Exposure method, substrate stage, exposure apparatus, and device manufacturing method

ABSTRACT

An exposure apparatus exposes a substrate by projecting a pattern image onto the substrate through a liquid. The exposure apparatus includes a projection optical system by which the pattern image is projected onto the substrate, and a movable member which is movable relative to the projection optical system. A liquid-repellent member, at least a part of a surface of which is liquid-repellent, is provided detachably on the movable member, the liquid-repellent member being different from the substrate.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation of U.S. patent application Ser. No. 11/448,927filed Jun. 8, 2006, which in turn is a Division of U.S. patentapplication Ser. No. 11/297,324 filed Dec. 9, 2005, which is aContinuation of International Application No. PCT/JP2004/008578, filedJun. 11, 2004, which claims priority to Japanese Patent Application Nos.2003-169904 (filed on Jun. 13, 2003), 2003-383887 (filed on Nov. 13,2003), and 2004-039654 (filed on Feb. 17, 2004). The disclosures of theaforementioned applications are incorporated herein by reference intheir entireties.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an exposure method by which a patternimage is exposed, via a projection optical system and a liquid, on asubstrate; to a substrate stage that supports a substrate; to anexposure apparatus; and to a device manufacturing method.

2. Description of Related Art

Semiconductor devices and liquid crystal display devices aremanufactured through the so-called photolithography technique, by whicha pattern formed on a mask is transferred onto a photosensitivesubstrate. The exposure apparatus used in the photolithography processhas a mask stage that supports a mask and a substrate stage thatsupports a substrate, and while successively moving the mask stage andthe substrate stage, transfers the mask pattern, via a projectionoptical system, onto the substrate. In recent years, to address theincreasingly high integration of device patterns, increasingly highresolution of the projection optical system has been desired. Theshorter the exposure wavelength used is, and, also, the larger thenumerical aperture of the projection optical system is, the higher theresolution of the projection optical system becomes. For this reason,the exposure wavelength used for the exposure apparatus is becomingshorter and shorter year by year, and the numerical aperture of theprojection optical system is also becoming larger and larger. In thiscontext, the presently dominant exposure wavelength is 248 nm from a KrFexcimer laser, but a still shorter wavelength of 193 nm from an ArFexcimer laser is now gradually being put to practical use.

In addition, when performing exposure, the depth of focus (DOF) is animportant factor along with the resolution. The resolution R and thedepth of focus δ are respectively expressed by the following formulas:R=k ₁ ·λ/NA,  (1)δ=±k ₂ ·λ/NA ²,  (2)where λ is the exposure wavelength, NA is the numerical aperture of theprojection optical system, and k₁ and k₂ are process coefficients. Itcan be seen from formulas (1) and (2) that if, to enhance the resolutionR, the wavelength λ is made shorter and the numerical aperture is madelarger, then the depth of focus δ becomes narrower.

When the depth of focus δ becomes too narrow, it becomes difficult tomake the substrate surface coincide with the image plane of theprojection optical system, and thus there occurs the possibility thatthe focus margin during the exposure operation will be insufficient. Toaddress this problem, the liquid immersion method, which is disclosedin, e.g., PCT International Publication No. WO 99/49504, has beenproposed as a method to make the exposure wavelength shorter in effectand to make the depth of focus broader. This liquid immersion method isdesigned to, by filling the space between the under surface of theprojection optical system and the substrate surface with a liquid, e.g.,water or organic solvent, to form a liquid immersion region and thus bytaking advantage of the fact that the wavelength of the exposure lightin the liquid becomes 1/n times (n is the refractive index of the liquidand is generally about 1.2 to 1.6) of that in the air, improve theresolution and, at the same time, enlarge the depth of focus byapproximately n times.

By the way, with the above-described related art, there are problems asdescribed below. The above-described prior art has adopted theconfiguration in which the space between the image plane side end faceof the projection optical system and the substrate (wafer) is locallyfilled with a liquid, and when exposing shot areas around the center ofthe substrate, the liquid does not flow out to the outside of thesubstrate. However, when, as shown by the schematic of FIG. 27,projection area 100 of the projection optical system is applied toperipheral area (edge area) E of substrate P for the purpose of exposingedge area E of substrate P, the liquid flows out to the outside ofsubstrate P, which leads to the disadvantage that the liquid immersionregion is not formed well, thus deteriorating the pattern imageprojected. Furthermore, there also arises the disadvantage that theliquid that flowed out causes mechanical parts, etc. in the vicinity ofthe substrate stage that supports substrate P to rust or causes electricleakage of the stage drive system, etc. Moreover, if the liquid thatflowed out finds its way over to the underside surface of the substrateand penetrates into the space between the substrate and the substratestage (substrate holder), there also arises the disadvantage that thesubstrate stage cannot hold the substrate well. In addition, air bubblesmay come to be mixed in the liquid due to the height difference or gapbetween substrate P and the substrate stage, and, in this case, therearises the disadvantage, for example, that the exposure light isscattered under the influence of the air bubbles or that the patterndoes not focus into an image on substrate P because of the bubbles.Besides, also when the liquid penetrates into the above-mentioned gap,rust or electric leakage may be induced.

SUMMARY OF THE INVENTION

The present invention has been made in consideration of such situations,and its objective is to provide an exposure method, a substrate stage,an exposure apparatus, and a device manufacturing method, by which, inthe case of performing exposure process with the space between aprojection optical system and a substrate being filled with a liquid,the exposure can be done in a condition that a liquid immersion regionis formed well, even when exposing edge areas of the substrate.

To resolve the above-described problems, the present invention adoptsthe following configurations that are illustrated in the embodiments andcorrespond to FIGS. 1 to 26.

An exposure method of the present invention is an exposure methodwherein a substrate is exposed by projecting an image of a pattern ontothe substrate via a projection optical system and a liquid, the sidesurface of the substrate is applied with liquid-repellent treatment.

In accordance with the present invention, because the side surface ofthe substrate is applied with liquid-repellent treatment, penetration ofthe liquid into, for example, the space between a member (substratestage) disposed so as to surround the substrate and the side surface ofthe substrate can be prevented. Thus, penetration of the liquid to theunderside surface side of the substrate can be prevented. Furthermore,mixing of bubbles with the liquid, for example, is also prevented, andthus, the edge areas of the substrate can be exposed in a condition thatthe liquid immersion region is formed well.

An exposure method of the present invention is an exposure methodwherein a substrate is exposed by projecting an image of a pattern ontothe substrate via a projection optical system and a liquid, theunderside surface of the substrate is applied with liquid-repellenttreatment.

In accordance with the present invention, because the underside surfaceof the substrate is applied with liquid-repellent treatment, penetrationof the liquid into, for example, the space between the substrate holderthat holds the underside surface of the substrate and the undersidesurface of the substrate can be prevented. Therefore, the exposure canbe performed with the substrate being held well.

A substrate stage of the present invention is a substrate stage that isused in liquid immersion exposure wherein a substrate is exposed byprojecting an image of a pattern onto the substrate via a projectionoptical system and a liquid and that is movable while holding thesubstrate, at least a part of its surface is liquid-repellent.

In accordance with the present invention, by making the surface of thesubstrate stage liquid-repellent, while suppressing scattering of theliquid, flowing out of the liquid to the outside of the substrate stage,mixing of bubbles with the liquid, penetration of the liquid into theinside of the substrate stage, etc., the edge areas of the substrate canbe exposed in a condition that the liquid immersion region is formedwell.

A substrate stage of the present invention is a substrate stage that isused in liquid immersion exposure wherein a substrate is exposed byforming a liquid immersion region on a part of the substrate and byprojecting a pattern image onto the substrate via a projection opticalsystem and a liquid and that holds the substrate, the substrate stagehas around the substrate a flat portion of which height is substantiallyequal to that of the substrate, in that a concave portion in which thesubstrate is disposed is formed inside the flat portion, and in that theexposure of the substrate is performed in a condition that a gap betweenthe flat portion and the substrate is filled with the liquid.

In accordance with the present invention, even when the liquid immersionregion is formed around the edge of the substrate, not only the liquidimmersion region can be maintained in good condition, but also mixing ofbubbles with the liquid of the liquid immersion region formed on a partof the substrate can be prevented. As a result, also around the edge ofthe substrate, good pattern images can be formed on the substrate.

An exposure apparatus of the present invention is provided with any oneof the substrate stages described above. A device manufacturing methodof the present invention uses the exposure method described above or anexposure apparatus described above provided with the substrate stage.

In accordance with the present invention, the edge areas of thesubstrate can be liquid immersion exposed in a condition that the liquidimmersion region is formed well, and thus devices having a desiredperformance can be manufactured.

A substrate stage of the present invention is a substrate stage that ismovable while holding a substrate as an object to be exposed, thesubstrate stage is provided with a first peripheral wall, a secondperipheral wall formed inside the first peripheral wall, and asupporting portion formed inside the second peripheral wall and in thatby applying a negative pressure to a space surrounded by the secondperipheral wall, the substrate is held by the supporting portion.

In accordance with the present invention, because at least doubleperipheral walls are provided with around the supporting portion thatsupports the substrate, even if a liquid penetrates into the spacebetween a member disposed so as to surround the substrate and the sidesurface of the substrate, penetration of the liquid to the undersidesurface side of the substrate or into a vacuum system for applying thenegative pressure to the space can be prevented.

A substrate stage of the present invention is a substrate stage that ismovable while holding a substrate as an object to be exposed, thesubstrate stage is provided with a supporting portion that supports thesubstrate, a flat portion which is disposed around the substratesupported by the supporting portion and is substantially coplanar withthe surface of the substrate, and a gap adjustment portion for makingthe gap between a cut portion of the substrate supported by thesupporting portion and the flat portion small.

In accordance with the present invention, by making the gap between thecut portion of the substrate and the flat portion surrounding thesubstrate small by means of the gap adjustment portion, penetration ofthe liquid into the space between the cut portion of the substrate andthe flat portion can be suppressed. Thus, penetration of the liquid to,e.g., the underside surface side of the substrate can be prevented.

A substrate stage of the present invention is a substrate stage that ismovable while holding a substrate as an object to be exposed, thesubstrate stage is provided with a peripheral wall and a supportingportion formed inside the peripheral wall, in that the peripheral wallis formed in accordance with the form or shape of a cut portion of thesubstrate, and in that by applying a negative pressure to a spacesurrounded the peripheral wall, the substrate is held by the supportingportion.

In accordance with the present invention, by forming the peripheral wallin accordance with the form of the cut portion of the substrate, thedisadvantage that a large gap would be formed between the substrate andthe peripheral wall will be suppressed, thus allowing the spacesurrounded by the peripheral wall to have smoothly a negative pressure.Thus, the substrate can be held well by the supporting portion, and,further, penetration of the liquid to the underside surface side of thesubstrate and/or into the space can be suppressed.

A substrate stage of the present invention is a substrate stage that ismovable while holding a substrate as an object to be exposed, thesubstrate stage is provided with a supporting portion for holding thesubstrate and a plurality of gas-suction ports for sucking and holdingthe substrate and in that the gas-sucking force near a cut portion ofthe substrate is made to be smaller than the gas-sucking forcetherearound.

In accordance with the present invention, by making the gas-suckingforce via the gas-suction port(s) near the cut portion, which tends tocreate a large gap between the substrate and the substrate stage,smaller (weaker) than the gas-sucking force via the gas-suction portstherearound, the disadvantage that the liquid would penetrate into thespace between the cut portion of the substrate and the substrate stagewill be suppressed. Thus, penetration of the liquid to the undersidesurface side of the substrate and/or into the gas-suction ports can beprevented.

An exposure apparatus of the present invention is by illuminating asubstrate held by any one of the substrate stage described above with anexposure light via a projection optical system and a liquid, thesubstrate is liquid immersion exposed. A device manufacturing method ofthe present invention uses the exposure apparatus described above.

In accordance with the present invention, while suppressing penetrationof the liquid to the underside side of the substrate, into the inside ofthe substrate stage, or into the vacuum system, the substrate can beliquid immersion exposed, and thus devices having a desired performancecan be manufactured.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram showing an embodiment of an exposureapparatus of the present invention.

FIG. 2 is a schematic showing a liquid supply system and a liquidrecovery system.

FIG. 3 is a plan view of a substrate stage.

FIG. 4 is a cross sectional view showing a main part of an embodiment ofa substrate stage of the present invention.

FIG. 5 is a schematic showing a substrate holder attachable to asubstrate stage.

FIG. 6 is a cross sectional view showing a main part of anotherembodiment of a substrate stage of the present invention.

FIGS. 7A to 7C are schematics showing an example of a procedure fordisposing a liquid in a space.

FIG. 8 is a cross sectional view showing a main part of anotherembodiment of a substrate stage of the present invention.

FIG. 9 is a plan view of a substrate stage related to another embodimentof the present invention.

FIG. 10 is a plan view of a substrate stage related to anotherembodiment of the present invention.

FIG. 11 is a plan view of a substrate stage related to anotherembodiment of the present invention.

FIG. 12 is a plan view of a substrate stage related to anotherembodiment of the present invention.

FIG. 13 is a drawing showing an embodiment of a substrate related to anexposure method of the present invention.

FIGS. 14A and 14B are plan views of a substrate stage related to anotherembodiment of the present invention.

FIGS. 15A and 15B are plan views of a substrate stage related to anotherembodiment of the present invention.

FIGS. 16A and 16B are drawings showing an embodiment of a substraterelated to an exposure method of the present invention.

FIG. 17 is a drawing respectively showing an embodiment of a substraterelated to an exposure method of the present invention.

FIG. 18 is a plan view of a substrate stage related to anotherembodiment of the present invention.

FIGS. 19A and 19B are cross sectional views respectively showing a mainpart of a substrate stage related to another embodiment of the presentinvention.

FIGS. 20A and 20B are cross sectional views respectively showing a mainpart of a substrate stage related to another embodiment of the presentinvention.

FIGS. 21A and 21B are drawings showing another embodiment of a gapadjustment portion related to the present invention.

FIG. 22 is a drawing showing another embodiment of a gap adjustmentportion related to the present invention.

FIG. 23 is a drawing showing another embodiment of a gap adjustmentportion related to the present invention.

FIG. 24 is a cross sectional view showing a main part of a substratestage related to another embodiment of the present invention.

FIGS. 25A and 25B are drawings of a substrate stage related to anotherembodiment of the present invention.

FIG. 26 is a flowchart showing an example of a semiconductor devicemanufacturing process.

FIG. 27 is a schematic for explaining problems of a prior art exposuremethod.

DETAILED DESCRIPTION OF THE INVENTION

Now, referring to the drawings, an exposure apparatus provided with asubstrate stage of the present invention will be described.

FIG. 1 is a schematic diagram showing an embodiment of an exposureapparatus of the present invention.

Referring to FIG. 1, exposure apparatus EX is provided with mask stageMST that supports mask M, substrate stage PST that supports substrate P,illumination optical system IL that illuminates mask M supported by maskstage MST with exposure light EL, projection optical system PL thatprojection exposes a pattern image of mask M illuminated with exposurelight EL onto substrate P supported by substrate stage PST, andcontroller CONT that controls the overall operation of exposureapparatus EX.

Exposure apparatus EX of the embodiment is a liquid immersion exposureapparatus, to which a liquid immersion method is applied, with theexposure wavelength being shortened in effect, to improve the resolutionand, at the same time, to widen the depth of focus. The exposureapparatus EX is provided with liquid supply system 10 that supply liquid1 onto substrate P and liquid recovery system 20 that recover liquid 1on substrate P. In the embodiment, purified water is used as liquid 1.Exposure apparatus EX, at least while transferring the pattern image ofmask M onto substrate P, forms, by liquid 1 supplied from liquid supplysystem 10, liquid immersion region AR2 on at least a portion onsubstrate P, with the portion including a projection area AR1 ofprojection optical system PL. More specifically, exposure apparatus EXfills the space between optical element 2 located at the end ofprojection optical system PL and the surface (exposure surface) ofsubstrate P with liquid 1, projects the pattern image of mask M ontosubstrate P via projection optical system PL and liquid 1 betweenprojection optical system PL and the substrate P, and thus exposessubstrate P.

Here, the embodiment will be described assuming, as an example, the casewhere as exposure apparatus EX, a scan type exposure apparatus (theso-called scanning stepper) in which while synchronously moving mask Mand substrate P in mutually different directions (opposite directions)along the scanning direction, the pattern formed on mask M is exposedonto substrate P is used. In the following description, it is assumedthat the direction that coincides with optical axis AX of projectionoptical system PL is referred to as the Z-axis direction, that thesynchronous movement direction (the scanning direction), in a planeperpendicular to the Z-axis direction, of mask M and substrate P isreferred to as the X-axis direction, and that the directionperpendicular to the Z-direction and to the X-direction is referred toas the Y-direction (the non-scanning direction). Furthermore, it isassumed that the direction around the X-axis, the direction around theY-axis, and the direction around the Z-axis are respectively referred toas the θX-direction, the θY-direction, and the θZ-direction. It shouldbe noted that a “substrate” referred to herein comprehends asemiconductor wafer over which a photoresist, a photosensitive material,is applied and that a “mask” comprehends a reticle on which a devicepattern to be reduction projected onto a substrate is formed.

Illumination optical system IL is for illuminating mask M supported bymask stage MST with exposure light EL and includes an exposure lightsource, an optical integrator for uniforming the illuminace of a lightflux emitted from the exposure light source, a condenser lens forcondensing exposure light EL from the optical integrator, a relay lenssystem, a variable field stop for setting an illumination area on mask Mformed by exposure light EL to be of a slit-like shape, etc. A specifiedillumination area on mask M is illuminated, by illumination opticalsystem IL, with exposure light EL having a uniform illuminancedistribution. As exposure light EL emitted from illumination opticalsystem IL, for example, a bright line of ultraviolet region (g-line,h-line, i-line) emitted from a mercury lamp, a deep ultraviolet light(DUV light) such as a KrF excimer laser light (wavelength of 248 nm),and a vacuum ultraviolet light (VUV light) such as an ArF excimer laserlight (wavelength of 193 nm) or an F₂ excimer laser light (wavelength of157 nm) may be used. In the embodiment, an ArF excimer laser light isused. As described above, liquid 1 of the embodiment is purified water,and the purified water can transmit exposure light EL even when theexposure light EL is an ArF excimer laser light. Purified water can alsotransmit a bright line of ultraviolet region (g-line, h-line, or i-line)and a deep ultraviolet light (DUV light) such as a KrF excimer laserlight (wavelength of 248 nm).

Mask stage MST is for supporting mask M, is two-dimensionally movable ina plane perpendicular to optical axis AX, i.e., in the XY-plane, and isfinely rotatable in the θZ-direction. Mask stage MST is driven by maskstage driver MSTD such as a linear motor. Mask stage driver MSTD iscontrolled by controller CONT. On mask stage MST is provided with movingmirror 50. Furthermore, laser interferometer 51 is positioned at aposition facing moving mirror 50. The two-dimensional position and therotation angle of mask M on mask stage MST are measured by laserinterferometer 51 in real time, and the measurement results areoutputted to controller CONT. By driving mask stage driver MSTD based onthe measurement results from laser interferometer 51, Controller CONTperforms positioning of mask M supported by mask stage MST.

Projection optical system PL is for projection exposing the pattern ofmask M onto substrate P at a predetermined projection magnification of βand is constituted by a plurality of optical elements, including opticalelement (lens) 2 disposed at the substrate P side end portion, and thoseoptical elements are supported by lens barrel PK. In the embodiment,projection optical system PL is a reduction system of which projectionmagnification β is, e.g., ¼ or ⅕. It should be noted that projectionoptical system PL may also be either a unit magnification system or amagnifying system. Note that optical element 2 at the end portion ofprojection optical system PL of the embodiment is detachably(exchangeably) disposed relative to lens barrel PK, and liquid 1 ofliquid immersion region AR2 is in contact with optical element 2.

Optical element 2 is made of fluorite. Since fluorite has a highaffinity for water, liquid 1 can be made to be in tight contact withsubstantially the entire surface of liquid contact surface 2 a ofoptical element 2. More specifically, since, in the embodiment, it isconfigured such that liquid (water) 1 having a high affinity for liquidcontact surface 2 a of optical element 2 is supplied, the highly tightcontact is effected between liquid contact surface 2 a of opticalelement 2 and liquid 1, so that the optical path between optical element2 and substrate P can be assuredly filled with liquid 1. It should benoted that optical element 2 may be made of quartz, which has a highaffinity for water. Furthermore, it may be configured such that liquidcontact surface 2 a of optical element 2 is applied with hydrophilic(lyophilic or liquid-attracting) treatment to enhance the affinity forliquid 1. In addition, since the portion around the end of lens barrelPK is to be in contact with liquid 1, at least the portion around theend is made of a rustproof metal, e.g., Ti (titanium).

Substrate stage PST is movable while supporting (holding) substrate P asan object to be exposed and is provided with Z stage 52 that holdssubstrate P via substrate holder PH, XY stage 53 that supports Z stage52, and base 54 that supports XY stage 53. Substrate stage PST is drivenby substrate stage driver PSTD such as a linear motor. Substrate stagedriver PSTD is controlled by controller CONT. By driving Z stage 52, theZ-direction position (focus position) and the θX- and θY-directionpositions of substrate P held by Z stage 52 are controlled. Furthermore,by driving XY stage 53, the XY-direction position (the position in thedirection substantially parallel to the image plane of projectionoptical system PL) of substrate P is controlled. More specifically, Zstage 52, by controlling the focus position and inclination angle ofsubstrate P, makes the surface of substrate P to coincide with the imageplane of projection optical system PL by means of an autofocus systemand an autoleveling system. XY stage 53 performs positioning ofsubstrate P in the X-axis and Y-axis directions. It is to be noted thatneedless to say, the Z stage and the XY stage may be integrallyconstructed.

On substrate stage PST (Z stage 52) is provided with moving mirror 55.Furthermore, laser interferometer 56 is positioned at a position facingmoving mirror 55. The two-dimensional position and the rotation angle ofsubstrate P on substrate stage PST are measured by laser interferometer56 in real time, and the measurement results are outputted to controllerCONT. By driving substrate stage driver PSTD based on the measurementresults from laser interferometer 56, controller CONT performspositioning of substrate P supported by substrate stage PST.

Furthermore, on substrate stage PST (Z stage 52) is provided with plate30 surrounding substrate P. Plate portion 30 is provided integrally withZ stage 52; and inside plate portion 30 is formed concave portion 32. Itshould be noted that plate portion 30 and Z stage 52 may be separatelyprovided. Substrate holder PH that holds substrate P is disposed inconcave portion 32. Plate portion 30 has flat surface (flat portion) 31of which height is substantially equal to that of the surface of thesubstrate P held by substrate holder PH disposed in concave portion 32.

Liquid supply system 10 is for supplying a predetermined liquid 1 ontosubstrate P and is provided with first liquid supply portion 11 andsecond liquid supply portion 12 that are capable of supplying liquid 1,first supply member 13 that has supply port 13A which is connected tofirst liquid supply portion 11 via supply pipe 11A having a flow channelto the supply portion and supplies onto substrate P liquid 1 deliveredfrom first liquid supply portion 11, and second supply member 14 thathas supply port 14A which is connected to second liquid supply portion12 via supply pipe 12A having a flow channel to the supply portion andsupplies onto substrate P liquid 1 delivered from second liquid supplyportion 12. First supply member 13 and second supply member 14 arepositioned close to the surface of substrate P and are respectivelydisposed in different positions in the surface direction of substrate P.Specifically, first supply member 13 of liquid supply system 10 isdisposed on one scanning direction side (−X side) relative to projectionarea AR1, and second supply member 14 is disposed on the other side (+Xside).

Each of first liquid supply portion 11 and second liquid supply portion12 has a tank that stores liquid 1, a pressurizing pump, etc. andsupplies liquid 1 onto substrate P via the pair of supply pipe 11A andthe pair of supply members 13 and supply pipe 12A and supply member 14,respectively. In addition, the liquid supply operations of first liquidsupply portion 11 and second liquid supply portion 12 are controlled bycontroller CONT, and controller CONT can control the per-unit-timeliquid supply amounts onto substrate P by first liquid supply portion 11and second liquid supply portion 12 independently of each other.Furthermore, each of first liquid supply portion 11 and second liquidsupply portion 12 has a temperature adjustment mechanism for the liquid,and it is configured such that liquid 1 having substantially the sametemperature as that inside a chamber (e.g., 23° C.) that accommodatesthe apparatus is supplied onto substrate P.

Liquid recovery system 20 is for recovering liquid 1 on substrate P andis provided with first recovery member 23 that has recovery port 23Apositioned close to the surface of substrate P, second recovery member24 that has recovery port 24A positioned close to the surface ofsubstrate P, first liquid recovery portion 21 that is connected to firstrecovery member 23 via recovery pipe 21A having a flow channel to therecovery member, and second liquid recovery portion 22 that is connectedto second recovery member 24 via recovery pipe 22A having a flow channelto the recovery member. Each of first liquid recovery portion 21 andsecond liquid recovery portion 22 has a suction device such as a vacuumpump, a tank that stores liquid 1 recovered, etc. and recovers liquid 1on substrate P via the pair of first recovery member 23 and recoverypipe 21A and the pair of second recovery member 24 and recovery pipe22A, respectively. The liquid recovery operations of first liquidrecovery portion 21 and second liquid recovery portion 22 are controlledby controller CONT, and controller CONT can control the per-unit-timeliquid recovery amounts by first liquid recovery portion 21 and secondliquid recovery portion 22.

With respect to the above-described first supply member 13, secondsupply member 14, first recovery member 23, and second recovery member24, at least the portions thereof that are in contact with the liquidare made of a material, which material includes stainless steels. In theembodiment, first supply member 13, second supply member 14, firstrecovery member 23, and second recovery member 24 are made of SUS 316, astainless steel. Furthermore, with respect to first supply member 13,second supply member 14, first recovery member 23, and second recoverymember 24, at least the liquid contact surfaces thereof that are incontact with the liquid are applied with some surface treatment. As suchsurface treatment, for example, “GOLDEP” treatment and “GOLDEP WHITE”treatment of Shinko Pantec Co., Ltd. can be listed.

FIG. 2 is a plan view showing the outline configuration of liquid supplysystem 10 and liquid recovery system 20. As shown in FIG. 2, projectionarea AR1 of projection optical system PL is set to be slit-shaped(rectangle-shaped) having its longitudinal direction in the Y-direction(non-scanning direction), and liquid immersion region AR2 filled withliquid 1 is formed on a part of substrate P so as to include projectionarea AR1. Furthermore, first supply member 13, of liquid supply system10, for forming liquid immersion region AR2 of projection area AR1 isdisposed on one scanning direction side (−X side) relative to projectionarea AR1, and second supply member 14 is disposed on the other side (+Xside).

Each of first supply member 13 and second supply member 14 is formed tobe substantially arc-shaped when viewed from the top, and theY-direction size of their respective supply port 13A and supply port 14Ais set to be, at the least, larger than the Y-direction size ofprojection area AR1. Furthermore, supply port 13A and supply port 14Athat are formed to be substantially arc-shaped when viewed from the topare arranged so that projection area AR1 is located therebetween. Liquidsupply system 10 simultaneously supplies liquid 1 on both sides ofprojection area AR1 via supply port 13A and supply port 14A of firstsupply member 13 and second supply member 14.

Each of first recovery member 23 and second recovery member 24 of liquidrecovery system 20 respectively has recovery port 23A and recovery port24A that are formed to be continuous, arc-shaped and to face the surfaceof substrate P. In addition, a substantially annular-shaped recoveryport is formed by first recovery member 23 and second recovery member 24that are disposed so as to face each other. Recovery port 23A of firstrecovery member 23 and recovery port 24A of second recovery member 24are disposed so as to surround first supply member 13 and second supplymember 14 of liquid supply system 10, and projection area AR1.Furthermore, inside the recovery port, which is continuously formed soas to surround projection area AR1, are provided with a plurality ofpartition members 25.

Liquid 1 that has been supplied onto substrate P from supply port 13Aand supply port 14A of first supply member 13 and second supply member14 is then supplied so that liquid 1 is spread while causing the wettingbetween the lower end surface of the end portion (optical element 2) ofprojection optical system PL and substrate P. In addition, liquid 1 thathas flowed out, relative to projection area AR1, to the outside of firstsupply member 13 and second supply member 14 is recovered by recoveryport 23A and recovery port 24A of first recovery member 23 and secondrecovery member 24, which are disposed, relative to projection area AR1,outside first supply member 13 and second supply member 14.

In the embodiment, when substrate P is scan-exposed, the per-unit-timeliquid supply amount of the liquid supplied, relative to the scanningdirection, in front of projection area AR1 is set to be larger than theliquid supply amount of the liquid supplied in the side oppositethereto. For example, when substrate P is exposed while substrate P ismoved in the +X-direction, controller CONT makes the liquid amount fromthe −X side relative to projection area AR1 (i.e., from supply port 13A)larger than the liquid amount from the +X side (i.e., from supply port14A); on the other hand, when substrate P is exposed while substrate Pis moved in the −X-direction, controller CONT makes the liquid amountfrom the +X side relative to projection area AR1 larger than the liquidamount from the −X side. Furthermore, the per-unit-time liquid recoveryamount of the liquid recovered, relative to the scanning direction, infront of projection area AR1 is set to be smaller than the liquidrecovery amount of the liquid recovered in the side opposite thereto.For example, when substrate P is moving in the +X-direction, the liquidrecovery amount at +X side relative to projection area AR1 (i.e., atrecovery port 24A) larger than the liquid recovery amount at the −X side(i.e., at recovery port 23A).

FIG. 3 is a plan view of Z stage 52 of substrate stage PST, when viewedfrom above. Moving mirrors 55 are disposed on the edge portions of Zstage 52 that is rectangle-shaped when viewed from the top, whichportions are perpendicular to each other. In addition, in substantiallythe center portion of Z stage 52 is formed concave portion 32; inconcave portion 32 is disposed substrate holder PH that holds substrateP. Around substrate P is provided with, integrally with Z stage 52,plate portion 30 that has flat surface (flat portion) 31 of which heightis substantially equal to the surface of substrate P.

Substrate holder PH has peripheral wall 33 that is substantiallyannular-shaped and a plurality of supporting portions 34 that aredisposed inside peripheral wall 33 and hold (support) substrate P.Peripheral wall 33 is disposed around supporting portions 34, andsupporting portions 34 are uniformly arranged inside peripheral wall 33.Flat surface 31 of plate portion 30 is disposed around substrate Psupported by supporting portions 34 and is provided so that it issubstantially coplanar with the surface of substrate P supported bysupporting portions 34. In addition, a predetermined gap A is formedbetween side surface PB of substrate P supported by supporting portions34 and plate portion 30. It should be noted that although, in thedrawing, the top surface of peripheral wall 33 has a relatively widewidth, it actually has a width of only about 1 to 2 mm.

Two corners of flat surface 31 of plate portion 30 are made to be wide;and on one of the wide portions is provided with fiducial mark FM thatis used when mask M and substrate P are aligned with a predeterminedposition. Also, around substrate P on substrate stage PST are providedwith various kinds of sensors such as an illuminance sensor. It is to benoted that although, in the embodiment, fiducial mark FM is provided onplate portion 30, a fiducial mark member, separate from plate portion30, for disposing fiducial mark FM may be provided on substrate stagePST.

FIG. 4 is an enlarged, cross sectional view showing a main part ofsubstrate stage PST holding substrate P. In FIG. 4, inside concaveportion 32 of Z stage 52 (plate portion 30) is disposed substrate holderPH that holds substrate P. Concave portion 32 is formed inside flatsurface 31, and inner side surface 36 of concave portion 32 is adjacentto flat surface 31. Peripheral wall 33 and supporting portions 34 formedinside peripheral wall 33 are provided on the substantially circulardisc-shaped base portion 35 that constitutes a portion of substrateholder PH. Each of supporting portions 34 is trapezoid-shaped as viewedin the cross section, and substrate P is held, at its underside surfacePC, by top surfaces 34A of the plurality of supporting portions 34. Itshould be noted that supporting portions 34 are illustrated in thedrawing as being relatively large, but, actually, a large number of verysmall pin-like supporting portions are formed inside peripheral wall 33.

Furthermore, top surface 33A of peripheral wall 33 is a flat surface.The height of peripheral wall 33 is lower than the height of supportingportions 34, and gap B is formed between substrate P held by supportingportions 34 and peripheral wall 33. Gap B is smaller than gap A betweeninner side surface 36 of concave portion 32 and side surface PB ofsubstrate P. For example, in consideration of the production toleranceof the outline of substrate P and of the positioning accuracy ofsubstrate P, gap A is preferably about 0.1 to 1.0 mm. In contrast, gap Bis about 2.0 to 5.0 μm. Furthermore, between inner side surface 36 ofconcave portion 32 and substrate holder PH's side surface 37 that facesinner side surface 36 is formed gap C. Here, the diameter of substrateholder PH is formed to be smaller than the diameter of substrate P, andthus gap A is smaller than gap C. It should be noted that, in theembodiment, no cut portion (orientation flat, notch, etc.) for aligningis formed on substrate P; substrate P is substantially circular; gap Ais from 0.1 to 1.0 mm around the entire circumference of substrate P;and thus, penetration of the liquid can be prevented.

Surface PA, which is the exposure surface of substrate P, is appliedwith a photoresist (photosensitive material) 90.

In the embodiment, photosensitive material 90 is a photosensitivematerial for ArF excimer laser (e.g., TARF-P6100 produced by TOKYO OHKAKOGYO CO., LTD.) and has liquid-repellency (water-repellency), and itscontact angle is about 70 to 80 degrees.

In addition, in the embodiment, side surface PB of substrate P isapplied with liquid-repellent treatment (water-repellent treatment).More specifically, over side surface PB of substrate P is also appliedthe above-mentioned photosensitive material 90 having liquid-repellency.Furthermore, over underside surface PC of substrate P is also appliedthe above-mentioned photosensitive material 90, and thus the undersidesurface is applied with liquid-repellent treatment.

A part of the surface of Z stage 52 (substrate stage PST) is appliedwith liquid-repellent treatment and is thus liquid-repellent. In theembodiment, flat surface 31 and inner side surface 36 of Z stage 52 haveliquid-repellency. In addition, a part of substrate holder PH is appliedwith liquid-repellent treatment and is thus liquid-repellent. In theembodiment, peripheral wall 33's top surface 33A and side surface 37 ofsubstrate holder PH have liquid-repellency. To implement theliquid-repellent treatment on Z stage 52 and substrate holder PH, forexample, a liquid-repellent material such as a fluoroplastic material oran acrylic plastic material is applied thereon, or a thin film made ofthe above-mentioned liquid-repellent material is attached thereon. Asthe liquid-repellent material to realize the liquid-repellency, amaterial nonsoluble in liquid 1 is used. It is to be noted that theentirety of Z stage 52 or substrate holder PH may be made of a materialhaving liquid-repellency (i.e., fluoroplastic).

Substrate stage PST has suction device 40 for applying a negativepressure to first space 38 surrounded by peripheral wall 33 of substrateholder PH. Suction device 40 has a plurality of suction ports 41provided on the top surface of base portion 35 of substrate holder PH,vacuum portion 42, provided outside substrate stage PST, including avacuum pump, and flow channel 43 that is formed inside base portion 35and that connects each of the plurality of suction ports 41 to vacuumportion 42. Suction ports 41 are provided at predetermined positions ofthe top surface of base portion 35 other than the positions occupied bysupporting portions 34. Suction device 40 sucks and holds substrate P onsupporting portions 34, by sucking the gas (air) in first space 38formed by and between peripheral wall 33, base portion 35, and substrateP supported by supporting portions 34 and thus by applying a negativepressure to first space 38. It should be noted that since gap B betweenunderside surface PC of substrate P and top surface 33A of peripheralwall 33 is very small, the negative pressure of first space 38 ismaintained.

Substrate stage PST is provided with recovery section (recovery means)60 that recovers liquid 1 that has flowed into second space 39 betweeninner side surface 36 of concave portion 32 and side surface 37 ofsubstrate holder PH. In the embodiment, recovery section 60 has tank 61that can store liquid 1 and flow channel 62 that is provided inside Zstage 52 and connects the space 39 to tank 61. In addition, the internalsurface of channel 62 is also applied with liquid-repellent treatment.

In Z stage 52 is formed flow channel 45 that connects second space 39between inner side surface 36 of concave portion 32 and side surface 37of substrate holder PH to the space that is outside Z stage 52 (theatmosphere). The gas (air) can communicate, via flow channel 45, betweensecond space 39 and the outside of Z stage 52; and second space 39 isset to have a pressure substantially equal to the atmospheric pressure.

As shown in FIG. 5, in the embodiment, substrate holder PH is detachablyprovided on Z stage 52. Furthermore, contact surface 57 of Z stage 52that comes into contact with substrate holder PH is applied withliquid-repellent treatment to have liquid-repellency; and also,underside surface 58 of substrate holder PH that comes into contact withZ stage 52 is applied with liquid-repellent treatment to haveliquid-repellency. As described above, to implement the liquid-repellenttreatment on contact surface 57 and underside surface 58, aliquid-repellent material such as a fluoroplastic material or an acrylicplastic material may be applied thereon, for example.

Next, a method by which edge areas E of substrate P are liquid immersionexposed by exposure apparatus EX having the above-describedconfiguration will be described.

As shown in FIG. 4, when liquid immersion exposing edge areas E ofsubstrate P, liquid immersion region AR2 of liquid 1 is formed so as tocover a part of surface PA of substrate P and a part of flat surface 31of plate portion 30. In this situation, since side surface PB ofsubstrate P and inner side surface 36 facing side surface PB are appliedwith liquid-repellent treatment, it is hard for liquid 1 of immersionregion AR2 to penetrate into gap A, and liquid 1 hardly flows into gap Abecause of its surface tension. Thus, even when exposing edge areas E ofsubstrate P, the liquid immersion exposure can be done with liquid 1being maintained well beneath projection optical system PL. During theexposure, since flat surface 31 of plate portion 30 is also applied withliquid-repellent treatment, liquid 1 forming immersion region AR2 isprevented from excessively wetting and extending to the outside of plateportion 30; and thus, immersion region AR2 can be formed well, and thedisadvantages such as flowing out or scattering of liquid 1 can beprevented as well. Also, since substrate P has no cut portion such as anotch, liquid 1 does not flow therethrough.

In addition, even if liquid 1 of immersion region AR2 slightly flows,via gap A, into second space 39, since each of underside surface PC ofsubstrate P and top surface 33A of peripheral wall 33 is applied withliquid-repellent treatment and since gap B is sufficiently small, liquid1 does not flow into first space 38 that is set to have a negativepressure in order to suck and hold substrate P on supporting portions34. Accordingly, disadvantages such as the disadvantage that liquid 1would flow into suction ports 41 and thus substrate P cannot besuck-and-held can be prevented.

Furthermore, liquid 1 that has flowed into second space 39 is recoveredby and into tank 61 of recovery section 60 via flow channel 62, whichsuppresses flowing out (leakage), scattering, or the like of liquid 1toward surrounding devices. Regarding the recovery process, since innerside surface 36 of concave portion 32 and side surface 37 of substrateholder PH, which surfaces form second space 39, and flow channel 62 areliquid-repellent, liquid 1 that has flowed into second space 39 flowssmoothly through flow channel 62 and is recovered by and into tank 61,without staying in second space 39.

By the way, there can be conceived the possibility that due to thesuction operation of suction device 40, the gas (air) in second space 39flows, via gap B, into first space 38, which causes liquid 1 ofimmersion region AR2 to penetrate, via gap A, into second space 39, thusdestabilizing the formation of immersion region AR2.

However, since gap C between inner side surface 36 of concave portion 32and side surface 37 of substrate holder PH is set to be larger than gapA between side surface PB of substrate P and inner side surface 36 ofconcave portion 32 and since second space 39 is open to the atmosphere,most of the air that passes through gap B is from the air that hasflowed into the space from the outside via flow channel 45 and haspassed through gap C, and thus the air that passes through gap Bincludes little of the air (liquid 1) that has passed through gap A.Therefore, the suction force exerted on the liquid 1 via gap A can bemade smaller than the surface tension of the liquid 1; and thus, thedisadvantage that liquid 1 of immersion region AR2 would flow, via gapA, into second space 39 can be suppressed.

It should be noted that it may be configured such that by connecting gas(air) supply device 45′ to one end portion of the flow channel oppositeto the other end portion to which second space 39 is connected, thussecond space 39 between inner side surface 36 of concave portion 32 andside surface 37 of substrate holder PH is made to have a positivepressure: more specifically, second space 39 is set to have a pressureslightly higher than the atmospheric pressure. Accordingly, thedisadvantage that liquid 1 of immersion region AR2 would flow, via gapA, into second space 39 can be suppressed. In this case if second space39 is made to have an excessive positive pressure, since there arisesthe disadvantage that the gas (air) in second space 39 flows, via gap A,into liquid 1 of immersion region AR2 and that bubbles come to be mixedin the liquid 1, second space 39 is preferably set to have a pressuresubstantially equal to the atmospheric pressure (i.e., slightly higherthan the atmospheric pressure).

As described above, since side surface PB of substrate P and inner sidesurface 36, facing side surface PB, of concave portion 32 are made to beliquid-repellent, the disadvantage that liquid 1 would penetrate, viagap A, into second space 39 between Z stage 52 and substrate holder PHcan be prevented. Thus, when exposing edge areas E of substrate P, theexposure can be performed in a condition that the liquid immersionregion AR2 is formed well, while suppressing, for example, mixing ofbubbles in liquid 1. In addition, since penetration of liquid 1 intosecond space 39 formed inside substrate stage PST can be prevented, therusting or electric leakage of the apparatus can be prevented.

Furthermore, since underside surface PC of substrate P and top surface33A, facing underside surface PC, of peripheral wall 33 are made to beliquid-repellent, the disadvantage that liquid 1 would penetrate, viagap B, into first space 38 can be prevented. Thus, the disadvantage thatliquid 1 would flow into suction ports 41 is avoided, and thus theexposure process can be performed in a condition that substrate P issuck-and-held well.

Furthermore, in the embodiment, since underside surface 58 of substrateholder PH attachable to Z stage 52 and contact surface 57 of Z stage 52that comes into contact with substrate holder PH are applied withliquid-repellent treatment, even if liquid 1 penetrates into secondspace 39, penetration of liquid 1 between underside surface 58 ofsubstrate holder PH and contact surface 57 of Z stage 52 can besuppressed. Thus, occurrence of rust on underside surface 58 ofsubstrate holder PH and contact surface 57 of Z stage 52 can beprevented. Furthermore, although when liquid 1 penetrates betweenunderside surface 58 of substrate holder PH and contact surface 57 of Zstage 52, there arises the situation that substrate holder PH and Zstage 52 adhere to each other and that it is difficult to separate them,the liquid-repellency of both has made them to be easily separated.

It should be noted that although, in the embodiment, substrate holder PHis attachable to substrate stage PST (Z stage 52), substrate holder PHand substrate stage PST may be integrally constructed.

It should be noted that although, in the embodiment, over the entiresurfaces of substrate P's surface PA, side surface PB, and undersidesurface PC are applied photosensitive material 90, it may be configuredsuch that only the region forming gap A, i.e., side surface PB ofsubstrate P, and the region forming gap B, i.e., the region of undersidesurface PC of substrate P that faces top surface 33A of peripheral wall33 are applied with liquid-repellent treatment. Furthermore, since whengap A is sufficiently small and when the liquid-repellency (contactangle) of the material applied to implement the liquid-repellenttreatment is sufficiently large, the possibility that liquid 1 wouldpenetrate, via gap A, into second space 39 further decreases, it may beconfigured such that without applying liquid-repellent treatment tounderside surface PC of substrate P that forms gap B, only the sidesurface PB of substrate P is applied with liquid-repellent treatment.

Similarly, other than the configuration in which the entire surface ofinner side surface 36 of concave portion 32 of substrate stage PST isapplied with liquid-repellent treatment, it may be configured such thatonly the partial region of inner side surface 36 that faces side surfacePB of substrate P is applied with liquid-repellent treatment.Furthermore, other than the configuration in which the entire surface oftop surface 33A of peripheral wall 33 is applied with liquid-repellenttreatment, it may be configured such that only a partial region of topsurface 33A, e.g., an inner side, annular region thereof, is appliedwith liquid-repellent treatment. Still further, other than theconfiguration in which the entire surface of side surface 37 ofsubstrate holder PH is applied with liquid-repellent treatment, it maybe configured such that only a partial region thereof is applied withliquid-repellent treatment.

Furthermore, although, in the embodiment, both of the side surface ofsubstrate P and inner side surface 36 that faces the side surface areapplied with liquid-repellent treatment, both of side surface 37 ofsubstrate holder PH and inner side surface 36 that faces side surface 37are applied with liquid-repellent treatment, and both of the undersidesurface of substrate P and top surface 33A of peripheral wall 33 areapplied with liquid-repellent treatment, it may be configured such thatonly one of each of those paired, facing surfaces is applied withliquid-repellent treatment.

Furthermore, in the embodiment, flat surface 31 of plate portion 30 isapplied with liquid-repellent treatment; however, since, for example,when flat surface 31 of plate portion 30 is sufficiently wide and/orwhen the scanning speed of substrate P relative to liquid 1 issufficiently low, the possibility that liquid 1 of immersion region AR2would flow out to the outside of plate portion 30 is small, flowing outor scattering of liquid 1 can be prevented, without applyingliquid-repellent treatment to flat surface 31. Furthermore, other thanthe configuration in which the entire surface of flat surface 31 isapplied with liquid-repellent treatment, it may be configured such thata partial region thereof, e.g., an annular region thereof in the closevicinity of substrate P, is applied with liquid-repellent treatment.

Furthermore, the liquid-repellency degree of flat surface 31 ofsubstrate stage PST may differ from that of inner side surface 36. Inother words, the contact angle of liquid 1 at flat surface 31 may differfrom the contact angle of liquid 1 at inner side surface 36.

It should be noted that although, in the embodiment, the height ofperipheral wall 33 is lower than the height of supporting portions 34,and thus gap B is formed between underside surface PC of substrate P andtop surface 33A of peripheral wall 33, underside surface PC of substrateP may be in contact with top surface 33A of peripheral wall 33.

Although, in the embodiment, to implement the liquid-repellent treatmenton side surface PB and underside surface PC of substrate P,photosensitive material 90 having liquid-repellency is applied thereto,side surface PB and/or underside surface PC may be applied with apredetermined material having liquid-repellency (water-repellency) otherthan photosensitive material 90. For example, while there is the casewhere a protective layer (a layer that protects photosensitive material90 from the liquid), called topcoat layer, is applied overphotosensitive material 90 that is applied over surface PA of substrateP, the exposure surface, the topcoat layer forming material (e.g.,fluoroplastic material) has a contact angle of, e.g., about 110 degreesand thus has liquid-repellency (water-repellency). Thus, the topcoatlayer forming material may also be applied to side surface PB and/orunderside surface PC of substrate P. Of course, a material havingliquid-repellency, other than photosensitive material 90 and the topcoatlayer forming material, may also be applied.

Furthermore, although, in the embodiment, to implement liquid-repellenttreatment on substrate stage PST and/or substrate holder PH, forexample, a fluoroplastic material or an acrylic plastic material isapplied thereon, the above-described photosensitive material or topcoatlayer forming material may be applied to substrate stage PST and/orsubstrate holder PH, and, contrariwise, the material used for theliquid-repellent treatment of substrate stage PST and/or substrateholder PH may be applied to side surface PB and/or underside surface PCof substrate P.

While the above-described topcoat layer is often formed to preventliquid 1 of immersion region AR2 from infiltrating photosensitivematerial 90, even if, for example, an adhesion trace (so-called watermark) of liquid 1 is formed on the topcoat layer, by removing thetopcoat layer after a liquid immersion exposure, a predetermined processsuch as a development process can be performed, with the water markbeing already removed together with the topcoat layer. Here, when thetopcoat layer is formed by, for example, a fluoroplastic material, thetopcoat layer can be removed by using a fluorinated solvent. By virtueof the process, devices such as the device for removing the water mark(i.e., a water mark removing substrate washer) can be dispensed with,and with the simple configuration in which the topcoat layer is removedby a solvent, a predetermined process can be performed with the watermark being already removed.

Next, referring to FIG. 6, another exposure apparatus embodimentprovided with a substrate stage of the present invention will bedescribed. Here, in the following description, the same or equivalentconstituent elements as those in the above-described embodiment aredenoted by the same reference numerals, and their descriptions will beabridged or omitted.

In substrate stage PST shown in FIG. 6, second space 39 between innerside surface 36 of concave portion 32 and side surface 37 of substrateholder PH can keep liquid 1. Here, side surface PB of substrate P of theembodiment is not applied with liquid-repellent treatment. Furthermore,with respect to underside surface PC of substrate P, only the partialregion thereof that faces top surface 33A of peripheral wall 33 isapplied with liquid-repellent treatment. It is to be noted that onsurface PA of substrate P, the exposure surface, is appliedphotosensitive material 90. Furthermore, in the embodiment, regardingsubstrate stage PST, inner side surface 36 and side surface 37 ofsubstrate holder PH are not applied with liquid-repellent treatment, butonly the top surface 33A of peripheral wall 33 of substrate holder PH isapplied with liquid-repellent treatment.

Regarding substrate holder PH, inside peripheral wall 33 is formedsecond peripheral wall 46.

Supporting portions 34 that support substrate P are formed inside secondperipheral wall 46. The height of peripheral wall 33 is made to besubstantially equal to that of second peripheral wall 46. The height ofperipheral wall 33 and the height of second peripheral wall 46 are lowerthan that of supporting portions 34. It should be noted that although,in the drawing, the width of top surface 46A of second peripheral wall46 is smaller than the width of top surface 33A of peripheral wall 33,the two height may be the same; or the width of top surface 46A ofsecond peripheral wall 46 may be made to be larger than the width of topsurface 33A of peripheral wall 33.

In addition, the height of top surface 46A of second peripheral wall 46may differ from the height of top surface 33A of peripheral wall 33, andtop surface 46A of second peripheral wall 46 may be in contact with theunderside surface of substrate P.

Furthermore, between peripheral wall 33 and second peripheral wall 46 isformed the annular buffer space 47. Flow channel 48 is connected tobuffer space 47. One end of flow channel 48 is connected to buffer space47, and the other end is connected to the space that is outsidesubstrate stage PST (the atmosphere). Thus, buffer space 47 betweenperipheral wall 33 and second peripheral wall 46 is open to theatmosphere, and the pressure of buffer space 47 is set to besubstantially equal to the atmospheric pressure.

Furthermore, substrate stage PST is provided with liquid supply device70 that can supply the liquid to second space 39. Liquid supply device70 has supply portion 71 that can feed the liquid and flow channel 72which is formed inside Z stage 52, one end of which is connected tosecond space 39, and the other end of which is connected to supplyportion 71. Here, liquid supply device 70 has also the function ofrecovering liquid 1 in second space 39.

FIGS. 7A to 7C are the drawings showing the procedure for filling secondspace 39 with liquid 1. As shown in FIG. 7A, before substrate P isloaded (mounted) on substrate stage PST, the water level (height) ofliquid 1 in second space 39 is set to be lower than the height ofperipheral wall 33. It is to be noted that it may be configured suchthat, in this stage, liquid 1 has been removed from second space 39.Next, as shown in FIG. 7B, after substrate P is loaded on substrateholder PH by a loading device, not shown, suction device 40 sucks thegas (air) in first space 38 surrounded by second peripheral wall 46 toapply a negative pressure to first space 38, and thus substrate P issuck-and-held by supporting portions 34 of substrate holder PH. Next, asshown in FIG. 7C, liquid 1 is supplied to second space 39 by liquidsupply device 70, and by this, second space 39 is filled with liquid 1.Here, liquid supply device 70 supplies liquid 1 to second space 39 untilthe liquid reaches the height (water level) substantially equal to theheight of flat surface 31 of plate portion 30 and of the surface ofsubstrate P held by substrate holder PH.

It should be noted that after a liquid immersion exposure is performed,the operations described with reference to FIGS. 7A to 7C can beperformed in reverse order. That is, after the liquid immersion exposureis performed, liquid supply device 70 combining the liquid recoveryfunction recovers liquid 1 in second space 39. Next, suction device 40stops the sucking and holding of substrate P by substrate holder PH.Next, an unloading device, not shown, unloads (carries out) substrate Pon substrate holder PH.

With space 39 being filled with liquid 1, flat surface 31 of plateportion 30 and surface PA of substrate P are substantially coplanar witheach other via the intervening liquid 1 of space 39. In other words, thegap between flat surface 31 and substrate P is filled with liquid 1. Forthis reason, even when liquid 1 is disposed on gap A to liquid immersionexpose edge areas E of substrate P, disadvantages such as thedisadvantage that bubbles would come to be mixed in the liquid 1 ofimmersion region AR2 are prevented, and the exposure can be performed ina condition that immersion region AR2 is formed well.

In this regard, since gap B is sufficiently small and since top surface33A of peripheral wall 33 and the partial region, facing top surface33A, of underside surface PC of substrate P are applied withliquid-repellent treatment, liquid 1 in second space 39 does not flow,via gap B, into buffer space 47. Furthermore, since buffer space 47 isopen to the atmosphere and is set to have substantially the atmosphericpressure, even in a condition that suction device 40 has applied anegative pressure to first space 38, flowing into buffer space 47 ofliquid 1 filling second space 39 can be prevented. Even if the liquidhas slightly passed through gap B, buffer space 47 can capture theliquid that has penetrated thereto.

Substrate stage PST of the embodiment has the configuration in which thestage is provided with liquid supply device 70 that can supply liquid 1to second space 39 and can also recover liquid 1 in second space 39. Byvirtue of this configuration, liquid 1 can be freely supplied orrecovered depending on whether substrate P is mounted on substrateholder PH, and thus flowing out of liquid 1 toward surrounding devicescan be prevented. More specifically, when filling second space 39 withliquid 1, it is conceivable, for example, that by arranging liquid 1 ofimmersion region AR2 on gap A and by applying a negative pressure tobuffer space 47 via flow channel 48, second space 39 is made to befilled with the liquid from liquid 1 on gap A; however, in this case,when substrate P is unloaded after a liquid immersion exposure isperformed, since the water level of liquid 1 of second space 39 ishigher than the height of peripheral wall 33, there arises thedisadvantage that liquid 1 flows to, for example, the side of topsurface 33A of peripheral wall 33 and/or of buffer space 47. However,since liquid supply device 70, which can supply liquid 1 to second space39 and can also recover liquid 1 in second space 39, is provided, whenunloading substrate P, liquid 1 in second space 39 can be recovered, andthus flowing out of liquid 1 can be prevented.

It should be noted that it may be configured such that by connecting gas(air) supply device 48′ to one end portion of follow channel 48 oppositeto the other end portion to which buffer space 47 is connected, bufferspace 47 is made to have a positive pressure: more specifically, bufferspace 47 is set to have a pressure slightly higher than the atmosphericpressure. By this setting, the disadvantage that liquid 1 of secondspace 39 would flow, via gap B, into buffer space 47 and furthermoreinto first space 38 can be suppressed. It is to be noted that if bufferspace 47 is made to have an excessive positive pressure, since therearises the disadvantage that liquid 1 in second space 39 flows togetherwith the gas (air) in buffer space 47, via gap A, into liquid 1 ofimmersion region AR2 and that bubbles come to be mixed in the liquid 1,buffer space 47 is preferably set to have a pressure substantially equalto the atmospheric pressure (i.e., slightly higher than the atmosphericpressure). Furthermore, it may also be configured such that the pressureof buffer space 47 can be freely adjusted, by making gas supply device48′ have a sucking function and by setting, by supply device 48′, thepressure of buffer space 47 between peripheral wall 33 and secondperipheral wall 46 to be, for example, slightly lower than theatmospheric pressure (low negative pressure) and be higher than thepressure of first space 38.

It should be noted that although, in the embodiment, it is configuredsuch that the partial region of underside surface PC of substrate P isapplied with liquid-repellent treatment, the entire surface of undersidesurface PC may be applied with liquid-repellent treatment, and sidesurface PB may also be applied with liquid-repellent treatment.Furthermore, side surface 37 of substrate holder PH and inner sidesurface 36 of concave portion 32 may be applied with liquid-repellenttreatment. Furthermore, only one of the surfaces of underside surface PCof substrate P and top surface 33A, facing the underside surface, ofperipheral wall 33 may be applied with liquid-repellent treatment.Furthermore, by, for example, applying with liquid-repellent treatmenton top surface 46A of second peripheral wall 46, the top surface ofsecond peripheral wall 46 may be made to be liquid-repellent. Of course,as with the above-described first embodiment and its modifications,substrate P, substrate holder PH, and substrate stage PST may also bemade to have liquid-repellency.

FIG. 8 is a drawing showing another embodiment of substrate stage PST ofthe present invention. In FIG. 8, substrate stage PST is provided withsecond suction device 80 that set the pressure of second space 39between inner side surface 36 of concave portion 32 and side surface 37of substrate holder PH to be lower than the pressure of first space 38surrounded by peripheral wall 33. Second suction device 80 is connectedto second space 39 via flow channel 62 and has tank 61 that can storeliquid 1 and pump 64 that is connected to tank 61 via valve 63. Theoperations of second suction device 80 and suction device 40 arecontrolled by controller CONT.

In the embodiment, side surface PB and underside surface PC of substrateP are not applied with liquid-repellent treatment. Also, inner sidesurface 36 of concave portion 32, side surface 37 of substrate holderPH, and top surface 33A of peripheral wall 33 are not applied withliquid-repellent treatment. When exposing edge areas E of substrate P,controller CONT controls the operations of suction device 40 and secondsuction device 80 and makes the pressure of second space 39 lower thanthe pressure of first space 38. Thus, liquid 1 of immersion region AR2on gap A, after flowing into second space 39 via gap A, is recovered byand into tank 61 of second suction device 80, without flowing to theside of first space 38 via gap B. Tank 61 has discharge flow channel61A, and it is configured such that when liquid 1 has pooled therein upto a predetermined amount, the liquid is discharged through flow channel61A.

As described above, with the pressure of second space 39 being made tobe lower than the pressure of first space 38, liquid 1 that has passedthrough gap A is recovered by and into tank 61 of second suction device80, without penetrating to the side of first space 38. Thus, with liquid1 being prevented from flowing into suction ports 41, a liquid immersionexposure can be performed in a condition that substrate P issuck-and-held well. Furthermore, since liquid 1 that has passed throughgap A is recovered by and into tank 61, the disadvantages such asflowing out or scattering to the outside of the device of liquid 1 canbe avoided.

As for the embodiment of FIG. 8 also, as described in connection withthe above-described embodiments and their modifications, at least a partof each surface of substrate P (e.g., its side surface), substrateholder PH (e.g., top surface 33A of peripheral wall 33), and substratestage PST (e.g., flat surface 31 and inner side surface 36) can be madeto be liquid-repellent.

Furthermore, although, in the embodiments of FIGS. 1 to 8, a partialsurface(s) of substrate stage PST and a partial surface(s) of substrateholder PH are applied with liquid-repellent treatment, all surfacesthereof may be applied with liquid-repellent treatment.

For example, top surface 34A of supporting portions 34 of substrateholder PH may be applied with liquid-repellent treatment. By thistreatment, formation of an adhesion trace (water mark) of the liquid issuppressed, and thus, the flatness of the supporting surface defined bythe plurality of supporting portions 34 can be maintained.

In sum, by applying liquid-repellent treatment to the surfaces withwhich the liquid (water) may be in contact or to which the liquid mayadhere, penetration, flowing out, and scattering of the liquid aresuppressed. In addition, even if the liquid adheres thereto, the liquidcan be easily removed.

By the way, in each of the above-described embodiments, substrate P issubstantially circular, and by disposing the substantially annular,plate portion 30 around the substrate, gap A having a width smaller thana predetermined value is formed between plate portion 30 (inner sidesurface 36 of concave portion 32) and side surface PB of substrate P;however, even in the case where substrate P has a cut portion such as anotch portion or an orientation flat portion (“orifla” portion), bysetting the shape of plate portion 30 (inner side surface 36 of concaveportion 32) in accordance with the cut portion of substrate P, the widthof gap A at the cut portion also can still be made to be smaller thanthe predetermined value.

FIG. 9 is a plan view of substrate stage PST supporting substrate Phaving notch portion NT, when viewed from above. As shown in FIG. 9,plate portion 30 is provided with protrusion portion 150 correspondingto the shape of notch portion NT of substrate P, and on inner sidesurface 36 of concave portion 32 of Z stage 52 is formed convex portion36N so as to form protrusion portion 150. Protrusion portion 150 has thefunction, as a gap adjustment portion, of making the gap between notchportion NT of substrate P supported by supporting portions 34 and flatsurface 31 of plate portion 30 small and is formed integrally with flatsurface 31 (plate portion 30). Gap A is thus formed between notchportion NT and protrusion portion 150. At the protrusion portion 150,the surface facing substrate P (notch portion NT) and the top surface ofprotrusion portion 150 are applied with liquid-repellent treatment aswith the embodiments earlier described; and, the side surface of notchportion NT of substrate P is also applied with liquid-repellenttreatment. It is to be noted that to implement the liquid-repellenttreatment on protrusion portion 150, for example, a fluoroplasticmaterial is applied thereon, as described above, and to implement theliquid-repellent treatment on notch portion NT, a photosensitivematerial is applied thereon. Of course, the above-described topcoatlayer forming material (e.g., fluoroplastic material) may also beapplied on notch portion NT.

Furthermore, on side surface 37 of substrate holder PH is formed concaveportion 37N, corresponding to the shape of notch portion NT, so as toface convex portion 36N of inner side surface 36 of concave portion 32,with the concave portion and convex portion being separated by apredetermined gap.

Furthermore, on the top surface of substrate holder PH that holdssubstrate P is provided peripheral wall 33N formed to correspond to theshape of notch portion NT; and, inside peripheral wall 33N are provideda plurality of supporting portions 34 and suction ports 41, as withthose in FIG. 3 (the portions and ports being omitted in FIG. 9).Furthermore, as with the above-described embodiments, the top surface ofperipheral wall 33N is liquid-repellent. When holding substrate P onsupporting portions 34, first space 38 (omitted in FIG. 9) surrounded byperipheral wall 33N is made to have a negative pressure, with the gasbeing sucked via suction ports 41. Since the shape of peripheral wall33N of substrate holder PH being also made to correspond to the shape ofnotch portion NT as describe above, even if the liquid penetrate intothe stage through gap A of notch portion NT, flowing, of the liquidpenetrated, to the inside of peripheral wall 33N can be prevented. It isto be noted that although notch portion NT is exaggerated in FIG. 9, theactual size thereof is about 2 to 3 mm, and the shape of notch portionNT is not limited to that shown in FIG. 9.

FIG. 10 is a plan view of substrate stage PST supporting substrate Phaving “orifla” portion OF, when viewed from above. As shown in FIG. 10,plate portion 30 is provided with flat portion 151 corresponding to theshape of “orifla” portion OF of substrate P, and on inner side surface36 of concave portion 32 of Z stage 52 is formed flat portion 36F so asto form flat portion 151. Flat portion 151 has the function, as a gapadjustment portion, of making the gap between orifla portion OF ofsubstrate P supported by supporting portions 34 and flat surface 31 ofplate portion 30 small and is formed integrally with flat surface 31(plate portion 30). Gap A is thus formed between “orifla” portion OF andflat portion 151. The surface facing substrate P (orifla portion OF) andthe top surface of flat portion 151 are applied with liquid-repellenttreatment; and, “orifla” portion OF is also applied withliquid-repellent treatment. It is to be noted that to implement theliquid-repellent treatment on flat portion 151, for example, afluoroplastic material is applied thereon, as described above, and toimplement the liquid-repellent treatment on “orifla” portion OF, aphotosensitive material is applied thereon.

Furthermore, on side surface 37 of substrate holder PH is formed flatportion 37F, corresponding to the shape of “orifla” portion OF, so as toface the flat portion of inner side surface 36 of concave portion 32,with flat portion 37F and the flat portion of inner side surface 36being separated by a predetermined gap. Furthermore, on the top surfaceof substrate holder PH that holds substrate P is provided peripheralwall 33F formed to correspond to the shape of orifla portion OF; and,inside peripheral wall 33F are provided a plurality of supportingportions 34 and suction ports 41, as with those in FIG. 3 (the portionsand ports being omitted in FIG. 10). Since the shape of peripheral wall33F of substrate holder PH being also made to correspond to the shape oforifla portion OF as describe above, even if the liquid penetrate intothe stage through gap A of orifla portion OF, flowing, of the liquidpenetrated, to the inside of peripheral wall 33F can be prevented.

As described above, by setting the shape of plate portion 30 inaccordance with the cut portion (notch portion or orifla portion) ofsubstrate P, the width of gap A can still be made to be smaller than thepredetermined value, and thus, penetration of liquid 1 between substrateP and substrate stage PST (plate portion 30) can be prevented.

By the way, when multiple substrates P are to be exposed, the size orshape of the cut portion (notch portion or orifla portion) may bedifferent from one another, and in such case, there arises thepossibility that gap A between the cut portion of substrate P and plateportion 30 cannot be kept to be smaller than the predetermined value.Furthermore, there is also the possibility that because of theproduction tolerance of the outline of substrate P and of thepositioning accuracy of substrate P relative to substrate stage PST, gapA between the cut portion of substrate P and plate portion 30 cannot bekept to be smaller than the predetermined value.

To address the above problems, by movably providing protrusion member152 having protrusion portion 152A corresponding to the shape of notchportion NT and by moving the protrusion member in the approaching orleaving direction relative to the substrate P, as shown in FIG. 11, gapA between notch portion NT and protrusion member 152 can be kept to besmaller than the predetermined value, even if, for example, the size ofnotch portion NT varies. In the embodiment shown in FIG. 11, protrusionmember 152 is disposed in concave portion 30D provided in a portion ofplate portion 30, and it is configured such that the protrusion memberis moved along the XY-plane by a driving mechanism, not shown. By movingprotrusion member 152 via the driving mechanism, controller CONT formsthe predetermined gap A between protrusion member 152 and notch portionNT. Furthermore, as with the above-described case, regarding protrusionmember 152, the surface facing substrate P (notch portion NT), the topsurface, and the surface facing concave portion 30D of plate portion 30are applied with liquid-repellent treatment; and, notch portion NT isalso applied with liquid-repellent treatment. Here, although gap D isformed between protrusion member 152 and plate portion 30 (concaveportion 30D), penetration of liquid 1 into gap D is prevented becausegap D is smaller than gap A and because concave portion 30D of plateportion 30 and the side surface, of protrusion member 152, facingconcave portion 30D of plate portion 30 are liquid-repellent. Note thatdescription of the same portions as those of FIG. 9 is omitted.

FIG. 12 is a drawing showing flat member 153 that is movably providedand that has flat surface 153A corresponding to the shape of “orifla”portion OF of substrate P. By moving flat member 153 in the approachingor leaving direction relative to the substrate P, gap A between oriflaportion OF and flat member 153 can be kept to be smaller than thepredetermined value, even if, for example, the size of orifla portion OFvaries.

In the embodiment shown in FIG. 12, flat member 153 disposed in concaveportion 30D provided in a portion of plate portion 30, and it isconfigured such that the flat member is moved along the XY-plane by adriving mechanism, not shown. By moving flat member 153 via the drivingmechanism, controller CONT forms the predetermined gap A between flatmember 153 and “orifla” portion OF. Furthermore, as with theabove-described case, regarding flat member 153, the surface facingsubstrate P (orifla portion OF), the top surface, and the surface facingconcave portion 30D of plate portion 30 are applied withliquid-repellent treatment; and, “orifla” portion OF is also appliedwith liquid-repellent treatment. Here, although gap D is formed betweenflat member 153 and plate portion 30 (concave portion 30D), penetrationof liquid 1 into gap D is prevented because gap D is smaller than gap Aand because concave portion 30D of plate portion 30 and the sidesurface, of flat member 153, facing concave portion 30D of plate portion30 are liquid-repellent. Note that description of the same portions asthose of FIG. 10 is omitted.

It should be noted that by replaceably disposing protrusion member 152(flat member 153) relative to substrate stage PST, by stockingbeforehand multiple protrusion members 152 (flat members 153) havingdifferent shapes or sizes, and by replacing protrusion member 152 (flatmember 153) in accordance with the shape or size of substrate P mountedon substrate stage PST, gap A can be kept to be smaller than thepredetermined value.

It should be noted that not only the size or shape of protrusion member152 (flat member 153) but also the manner in which protrusion member 152(flat member 153) moves, e.g., the movement direction thereof, are notlimited by the above-described embodiments; in sum, accomplishment ofthe condition that gap A in the vicinity of the cut portion of substrateP is smaller than the predetermined value would suffice.

It should be noted that while, in the embodiments, it is configured suchthat protrusion member 152 (flat member 153) is moved so that gap A isformed between the cut portion (notch portion or orifla portion) ofsubstrate P and protrusion member 152 (flat member 153), it may also beconfigured such that plate portion 30 to be disposed around substrate Pis disposed movably along the XY-plane to adjust gap A between substrateP and plate portion 30 to be smaller than the predetermined value. Inthis case, for example, the configuration in which plate portion 30 isdivided into multiple parts and each of the divided parts are moved,along the XY-plane, in the approaching or leaving direction relative tothe substrate P can be adopted. In implementing this configuration, bysetting the each of gaps between the divided parts to have a gap throughwhich the liquid cannot penetrate, the disadvantage that the liquidwould penetrate to the inside of substrate stage PST can be avoided.

Furthermore, it may also be configured such that before substrate P iscarried in (loaded) on substrate stage PST, the size and/or shape(deformation) of substrate P or the size and/or shape of the cut portionof substrate P is measured and then based on the measurement results,each members are moved so that gap A is made to be smaller than thepredetermined value. By this, not only penetration of the liquid fromgap A can be prevented more certainly, but also damage to the edge ofsubstrate P can be prevented.

Furthermore, regarding the above-described embodiment of FIG. 6, thereis the possibility that the liquid flows over top surface 33A ofperipheral wall 33 (46); however, since the liquid that has flowedbeyond top surface 33A of peripheral wall 33 can be captured by bufferspace 47, flowing of the liquid into first space 38 can be prevented. Itis to be noted that preparing for such case, it may be configured suchthat the liquid that has penetrated into buffer space 47 is recovered.

Next, another embodiment of the present invention will be described. Inthe embodiments described above with reference to FIGS. 9 to 12, it isconfigured such that to prevent liquid 1 from penetrating between thecut portion (notch portion or orifla portion) of substrate P supportedsupporting portions 34 and flat surface 31 of plate portion 30,protrusion portion 150, flat portion 151, the movable protrusion member152, and the movable flat member 153 are, as gap adjustment portions,provided. On the other hand, as indicated by reference mark NT′ of FIG.13, by making notch portion NT′ of substrate P small, as far aspossible, to the extent that liquid 1 does not penetrate, penetration ofliquid 1 between the notch portion of substrate P and substrate stagePST (plate portion 30) can also be prevented. Note that the not portionshown in FIG. 13 has a rounded shape having no acutely-angled portion.

By the way, there is a case where when mounting substrate P on substratestage PST, the substrate is mounted on substrate stage PST, with theposition of cut portion being differently positioned relative tosubstrate stage PST, in accordance with the process condition of thecircuit and/or with the pattern of mask M. For example, there is a casewhere when mounting a first substrate on substrate stage PST, thesubstrate is mounted in a condition that the cut portion is directed tothe −Y side and where when mounting a second substrate on substratestage PST, the substrate is mounted in a condition that the cut portionis directed to the +X side. To address this case, it may be configuredsuch that by movably providing plate portion 30 having protrusionportion 150, plate portion 30 is rotated in accordance with the positionof cut portion of substrate P supported by supporting portions 34. Forexample, when, as shown in FIG. 14A, making supporting portions 34support substrate P so that notch portion NT is directed to −Y side,plate portion 30 is rotated so that protrusion portion 150 is directedto −Y side in accordance with the position of notch portion NT; and,when, as shown in FIG. 14B, making supporting portions 34 supportsubstrate P so that notch portion NT is directed to +X side, plateportion 30 is rotated so that protrusion portion 150 is directed to +Xside in accordance with the position of notch portion NT. In this case,although not shown in FIGS. 14A and 14B, substrate holder PH on whichperipheral wall 33N having concave portion 37N also rotates inaccordance with the position of notch portion NT. It may be, asdescribed above, configured such that protrusion portion 150 (and convexportion 36N), a gap adjustment potion, is provided movably in therotation direction (OZ-direction). Similarly, plate portion 30 havingflat portion 151 and substrate holder on which peripheral wall 33Fhaving flat portion 37F is formed may be provided so that they rotate inaccordance with the position of “orifla” portion OF. By adopting suchconfigurations, penetration of liquid 1 between plate portion 30 andsubstrate P (cut portion) can also be prevented, irrespective of theposition of the cut portion of substrate P.

Also, it may be configured such that the totality of substrate stage PSTis rotated so that protrusion portion 150 of plate portion 30 is alignedwith the position of notch portion NT of substrate P supported bysupporting portions 34.

In FIG. 15A is shown the condition that notch portion NT is directed tothe −Y side; in FIG. 15B is shown the condition that notch portion NT isdirected to the +X side. Here, when, as shown in FIGS. 15A and 15B, forexample, laser interferometer 56X is disposed in a position separated,on the +X side, from substrate stage PST, and laser interferometer 56Yis disposed in a position separated on the −Y side, by positioningmoving mirror 55 on each of at least three edge portions of substratestage PST formed in a rectangle-shape as viewed from the top, each oflaser interferometers 56X and 56Y can be made to face either one of themoving mirrors 55, also when substrate stage rotates.

By the way, the cut portion of substrate P is primarily used during thepre-alignment process, a rough alignment process when substrate P ismounted on substrate stage PST. More specifically, with the position ofthe cut portion being first detected optically, the pre-alignmentprocess is performed based on the detection results. Thus, as shown inFIG. 16A, by covering notch portion (cut portion) NT formed on substrateP with covering member 300 having light transmittance, notch portion NTcan be optically detected via covering member 300, and, at the sametime, the disadvantage that when substrate P is mounted on substratestage PST, a large gap would be formed between plate portion 30 andnotch portion NT (covering member 300) can be prevented. Similarly, itmay be configured such that “orifla” portion OF is covered with acovering member.

It should be noted that when, as shown in FIG. 16B, notch portion (cutportion) NT is formed in each of multiple positions of substrate P, itmay be configured such that each of the multiple notch portions NT iscovered with covering member 300. Furthermore, when notch portion NT isformed in each of multiple positions of substrate P, it may beconfigured, instead of covering such notch portions with coveringmembers 300, such that multiple protrusion portions 150 are provided onplate portion 30 (substrate stage PST) in accordance with the multiplenotch portions NT. By adopting such configurations, penetration ofliquid 1 between plate portion 30 and substrate P (cut portion) can alsobe prevented.

Also, by providing a hole portion in a predetermined position ofsubstrate P, instead of forming the cut portion on substrate P,substrate P can be pre-aligned by optically detecting the hole portion.In this case, the hole portion may be a through-hole having a smalldiameter sufficient not to allow liquid 1 to pass through the hole ormay a dimple-shaped hole (concave portion) that does not pierce throughsubstrate P. In FIG. 17 is shown an embodiment where a group of multiplesmall through-holes 301 having a diameter of, e.g., about 0.5 mm isformed in a predetermined position of substrate P.

FIG. 18 is a plan view illustrating another embodiment of the presentinvention. Note that the same members as those of FIG. 4 are denoted bythe same reference numerals, and detailed descriptions thereof areomitted. In FIG. 18, each of protrusion members 152, as a gap adjustmentportion, is provided in each of the multiple positions in the vicinityof the edge of substrate P supported by supporting portions 34. In theembodiment shown in FIG. 18, first protrusion member 152Y is provided inthe vicinity of the −Y side edge of substrate P; second protrusionmember 152X is provided in the vicinity of the +X side edge of substrateP. Each of protrusion members 152Y and 152X is provided movably in theZ-axis direction (in the vertical direction). In addition, a single cutportion (notch portion NT) is formed in the vicinity of the −Y side edgeof substrate P.

FIG. 19A is a cross sectional view illustrating first protrusion member152Y and its vicinity; FIG. 19B is a cross sectional view illustratingsecond protrusion member 152X and its vicinity. As shown in FIGS. 19Aand 19B, protrusion members 152 (152Y and 152X) are supported by elasticmember 302. In the embodiment shown in FIGS. 19A and 19B, elastic member302 is constituted by a coil spring member, and protrusion members 152are supported, via the coil spring member, by the top surface (contactsurface) 57 of Z stage 52. In a state in which notch portion NT, ofsubstrate P, directed to the −Y side and protrusion member 152Y arealigned with each other, protrusion member 152Y is disposed, as shown inFIG. 19A, inside notch portion NT by the upward biasing force of coilspring member 302 without being pressed by substrate P. By virtue ofprotrusion member 152Y, the gap between notch portion NT of substrate Psupported by supporting portions 34 and flat surface 31 of plate portion30 can be made to be small. On the other hand, as shown in FIG. 19B,protrusion member 152X disposed in the position where notch portion doesnot exist is pressed from above by substrate P, and coil spring member302 shortens. Thus, protrusion member 152X is disposed under substrateP. In contrast, when substrate P is supported by supporting portions 34in a state in which notch NT is directed to the +X side, protrusionmember 152X is disposed inside notch portion NT, and protrusion member152Y is disposed under substrate P.

By adopting the configuration just described, the gap between notchportion NT of substrate P supported by supporting portions 34 and flatsurface 31 of plate portion 30 can be made to be small. Furthermore, byapplying, for example, with liquid-repellent treatment on the topsurface and side surface of protrusion members 152 to make themliquid-repellent, as with flat surface 31 and inner side surface 36 ofplate portion 30, penetration of liquid 1 can be prevented moreeffectively.

FIGS. 20A and 20B are cross sectional views illustrating anotherembodiment of the present invention. The embodiment of FIGS. 20A and 20Bis a modification of the embodiment of FIGS. 19A and 19B, and the samemembers of the former as those of the latter are denoted by the samereference numerals. In FIG. 20, the under surface of protrusion member152 is connected to the top end portion of the rod-shaped supportingmember 303. In a portion of Z stage 52 is provided through-hole 52K, andsupporting member 303 is disposed, inside through-hole 52K, movably inthe Z-direction. The lower end portion of supporting member 303protrudes from the under surface of Z stage 52, and the lower endportion of supporting member 303 is connected to collar member 304.Furthermore, leaf spring member 305 attached to the under surface of Zstage 52 is in contact with the under surface of collar member 304. Aswith the embodiment of FIGS. 19A and 19B, in a state in which notchportion NT of substrate P and protrusion member 152 are aligned witheach other, protrusion member 152 is lifted upward by the biasing forceof leaf spring member 305 and is disposed inside notch portion NT, asshown in FIG. 20A. On the other hand, in a state in which notch portionNT of substrate P and protrusion member 152 are not aligned with eachother, protrusion member 152 is pressed by substrate P and is disposedunder substrate P, as shown in FIG. 20B. Also in this case, by makingthe top surface and side surface of protrusion member 152liquid-repellent, penetration of liquid 1 can be prevented effectively.

FIGS. 21A and 21B are cross sectional views illustrating anotherembodiment of the present invention. In FIGS. 21A and 21B, protrusionmember 152 is connected, via hinge portion 306, to plate portion 30 (ora predetermined position of substrate stage PST). In FIGS. 21A and 21B,hinge portion 306 supports, rotatably in the θY-direction, protrusionmember 152. Furthermore, hinge portion 306 has a spring member built-inand supports protrusion member 152 so as to bias it in the direction ofy1 arrow in FIG. 21B. In other words, hinge portion 306 exerts a biasingforce upon protrusion member 152 in the direction such that the topsurface of protrusion member 152 and the surface of substrate Pconstitute a single plane. It is to be noted that hinge portion 306 hasa stopper, and the rotation of protrusion member 152 is stopped when thetop surface of protrusion member 152 and the surface of substrate Psubstantially constitute a single plane. Thus, in a state in which notchportion NT of substrate P and protrusion member 152 are aligned witheach other, protrusion member 152 is disposed inside notch portion NT,as shown in FIG. 21A. On the other hand, in a state in which notchportion NT of substrate P and protrusion member 152 are not aligned witheach other, protrusion member 152 is pressed by substrate P and isdisposed under substrate P, as shown in FIG. 21B. Also in this case, bymaking the top surface and side surface of protrusion member 152liquid-repellent, penetration of liquid 1 can be prevented effectively.

It should be noted that while, in the above-described embodiments, it isconfigured such that protrusion members 152 is moved by a spring member,it may also be configured such that protrusion member 152 is moved byusing a predetermined actuator. In this case, for example, beforesubstrate P is mounted on substrate stage PST, the position informationof notch portion NT is obtained. Furthermore, after substrate P ismounted on substrate stage PST, a specified protrusion member 152 amongthe multiple protrusion members 152 provided on substrate stage PST isdriven, based on the obtained position information, by using theactuator to dispose the specified protrusion member 152 inside notchportion NT. Furthermore, it may also be configured such that protrusionmember 152 is detachably provided on substrate stage PST, and anoperator, for example, manually disposes protrusion member 152 insidenotch portion NT of substrate P on substrate stage PST, without using anactuator. Still further, it may also be configured such that a robot armthat can hold protrusion member 152 detachable relative to substratestage PST disposes protrusion member 152 inside notch portion NT ofsubstrate P on substrate stage PST.

FIG. 22 illustrates an embodiment in which protrusion member 152 isdisposed inside notch portion NT by using an actuator. In FIG. 22,protrusion member 152 is attached to one end portion (edge portion) ofthe rod-shaped supporting member 307, and the other end portion (baseportion) of supporting member 307 is connected to actuator 308. Actuator308 can rotate supporting member 307, to which protrusion member 152 isattached, with the base portion of supporting member 307 being therotation center. In FIG. 22, actuator 308 rotates supporting member 307in the θY-direction. By rotating supporting member 307, actuator 308 candispose protrusion member 152 attached to the edge portion of supportingmember 307 inside notch portion NT. Also in this case, by making the topsurface and side surface of protrusion member 152 liquid-repellent,penetration of liquid 1 can be prevented effectively. Furthermore, aftera liquid immersion exposure is performed, actuator 308 can, by rotatingsupporting member 307 in the reverse direction, remove protrusion member152 from notch portion NT of substrate P.

Also, by covering notch portion NT with sheet member 309 as shown inFIG. 23, penetration of liquid 1 between notch portion NT and plateportion 30 (flat surface 31) can be suppressed. Sheet member 309 ispreferably liquid-repellent; and, for example, a sheet member made ofpolytetrafluoroethylene (TEFLON (registered trademark)) can be used assheet member 309.

In addition, it may be configured such that sheet member 309 is formedto be annular-shaped, and such sheet member 309 covers the entirety ofthe gap between substrate P and flat surface 31.

Furthermore, in each of the above-described embodiments, protrusionmember 152 is preferably replaceable. While protrusion member 152 ispreferably liquid-repellent, the liquid-repellency may deteriorate withtime. Thus, by replacing protrusion member 152 when itsliquid-repellency has deteriorated, penetration of liquid 1 can beprevented effectively by using another protrusion member 152 havingdesired liquid-repellency.

Furthermore, although, in each of the above-described embodiments, theconfiguration in which protrusion member 152 is disposed in notchportion NT was described by way of illustration, such configuration canalso, of course, be applied to a flat member corresponding to “orifla”portion OF formed on substrate P. In this case, by using an elasticmember (spring member), the flat member is disposed in a predeterminedposition; the gap between “orifla” portion OF of substrate P supportedby supporting portions 34 and flat surface 31 of plate portion 30 ismade to be small; and thus, penetration of liquid 1 can be prevented.

Furthermore, needless to say, the embodiments described with referenceto FIGS. 1 to 8 and their modifications may be appropriately combinedwith the embodiments described with reference to FIGS. 9 to 23 and theirmodifications.

FIG. 24 is a cross sectional view showing another embodiment of thepresent invention. Note that description of the same members as those ofFIGS. 4, 6, and 8 is omitted. In FIG. 24, substrate stage PST isprovided with peripheral wall 33, second peripheral wall 46 formedinside peripheral wall 33, and supporting portions 34 formed insidesecond peripheral wall 46. Suction device 40 performs the suctionoperation, via suction ports 41, to apply a negative pressure to firstspace 38 surrounded by second peripheral wall 46, and thus substrate Pis suck-and-held by supporting portions 34.

Furthermore, the pressure of buffer space 47 between peripheral wall 33and second peripheral wall 46 is set to be higher than the pressure offirst space 38 surrounded by second peripheral wall 46. Morespecifically, as with the embodiment described referring to FIG. 6,buffer space 47 is, via flow channel 48, open to the atmosphere, and thepressure of buffer space 47 is set to be substantially equal to theatmospheric pressure. Alternatively, by using gas supply device 48′ havea pressure adjustment function, buffer space 47 may be set to have apressure slightly higher than the atmospheric pressure, or may be set tohave a pressure lower than the atmospheric pressure and higher than thepressure of first space 38 (i.e., low negative pressure).

The height of peripheral wall 33 is set to lower than that of supportingportions 34. The height of second peripheral wall 46 is also set tolower than that of supporting portions 34. Furthermore, top surface 33Aof peripheral wall 33 is applied with liquid-repellent treatment to haveliquid-repellency, and top surface 46A of second peripheral wall 46 isalso applied with liquid-repellent treatment to have liquid-repellency.

It is to be noted that it may also be configured such that only one ofthe surfaces of top surface 33A of first peripheral wall 33 and topsurface 46A of second peripheral wall 46 is made to be liquid-repellent.

In contrast to FIG. 6, in the embodiment, second space 39 between innerside surface 36 of concave portion 32 and side surface 37 of substrateholder PH is not filled with liquid 1. Furthermore, to second space 39is connected second suction device 80 for adjusting the pressure ofsecond space 39 and, at the same time, for recovering liquid 1 that hasflowed, via gap A, into second space 39. Second suction device 80 has anconfiguration equivalent to the configuration described referring toFIG. 8 and can make the pressure of second space 39 lower than thepressure of buffer space 47. By this, even if liquid 1 penetrateslightly from gap A, penetration, of the liquid 1 having penetrated,into buffer space 47 through gap B between top surface 33A of firstperipheral wall 33 and substrate P can be suppressed. In addition,second suction device 80 can recover the liquid that has penetrated intosecond space 39.

It is to be noted that it may also be configured such that, as shown inFIG. 4, only with tank 61 is provided, without pump 64 and valve 63being provided. Still further, it may also be configured such that, asshown in FIG. 4, second space 39 is open to the atmosphere.

In this case, the pressure of buffer space 47 is set to be slightlyhigher than the atmospheric pressure by using gas supply device 48′. Bythis, even if liquid 1 penetrate slightly from gap A, penetration, ofthe liquid 1 having penetrated, into buffer space through gap B betweentop surface 33A of first peripheral wall 33 and substrate P can besuppressed. In addition, the liquid that has penetrated into secondspace 39 can be recovered.

When holding substrate P by and on supporting portions 34, first space38 is made to have a negative pressure, and, at the same time, thepressure of buffer space 47 is made to be higher than that of firstspace 38. Preferably, the pressure of buffer space 47 is made to besubstantially equal to the atmospheric pressure or to be higher than theatmospheric pressure. By this setting, even if liquid 1 has penetratedinto second space 39 through gap A, since the pressure of buffer space47 is set to be higher, the disadvantage that liquid 1 would penetrate,via buffer space 47, into first space 38 and furthermore to theunderside surface of substrate P or into suction ports 41 is prevented.Furthermore, in the embodiment, even when the cut portion of substrate Pis positioned on top surface 33A of peripheral wall 33, the disadvantagethat liquid 1 that has penetrated between the cut portion and flatsurface 31 would penetrate to the side of buffer space 47 or of firstspace 38 can be reduced.

Furthermore, while there is the possibility that the liquid flows beyondtop surface 33A of peripheral wall 33 depending on the size of the cutportion of substrate P, since the liquid that has flowed beyond topsurface 33A of peripheral wall 33 can be captured by buffer space 47,penetration of the liquid into first space 38 can be prevented. It is tobe noted that preparing for such case, it may be configured such thatthe liquid that has penetrated into buffer space 47 is recovered.

In addition, although detailed description is omitted, it may beconfigured such that, as with the embodiment shown in FIG. 4, sidesurface PB of substrate P, underside surface PC of substrate P, flatsurface 31 of plate portion 30, and/or inner side surface 36 of plateportion 30 are made to be liquid-repellent.

In other words, the liquid-repellent treatments of at least a part ofeach surface of substrate P, substrate holder PH, and substrate stagePST, as described in connection with the embodiment of FIG. 4 and itsmodifications, can be appropriately combined with the embodiment of FIG.24.

It should be noted that since, in the embodiment of FIG. 24, thenegative pressure of first space 38 can be maintained by secondperipheral wall 46, a cut portion to communicate buffer space 47 andsecond space 39 with each other may be provided on a portion of firstperipheral wall 33.

FIGS. 25A and 25B are drawings illustrating another embodiment of thepresent invention; FIG. 25A is a plan view; FIG. 25B is across-sectional view taken along the arrow A-A of FIG. 25A. Note thatthe same members as those of FIG. 3 are denoted by the same referencenumerals, and detailed descriptions thereof are omitted. In FIGS. 25Aand 25B, substrate stage PST is provided with a plurality of suctionports (air suction ports) 41 for suck-and-holding substrate P onsupporting portions 34. Furthermore, on an inside portion of peripheralwall 33 is locally formed second peripheral wall 46′.

As shown in FIG. 25A, second peripheral wall 46′ is provided in aposition corresponding to notch portion NT (or orifla portion) ofsubstrate P supported by supporting portions 34. Second peripheral wall46′ has top surface 46A′ that is substantially arc-shaped as viewed fromthe top, and both ends of the peripheral wall are connected toperipheral wall 33. Furthermore, between peripheral wall 33 and secondperipheral wall 46′ is formed buffer space 47′. Buffer space 47 isformed in the vicinity of notch portion NT of substrate P supported bysupporting portions 34. In the embodiment also, each of the heights ofperipheral wall 33 and second peripheral wall 46′ is set to be lowerthan the height of supporting portions 34, the top surfaces ofperipheral wall 33 and second peripheral wall 46′ haveliquid-repellency.

The plurality of suction ports 41 provided in first space 38 areconnected, via flow channel 43, to vacuum portion (vacuum system) 42. Onthe other hand, suction ports 41′ provided in buffer space 47′ locatedin the vicinity of notch portion NT of substrate P are connected, viasecond flow channel 43′, to second vacuum portion (second vacuum system)42′ provided separately from vacuum portion 42. The suction force(per-unit-time gas suction amount) of second vacuum portion 42′ is setto be weaker than that of vacuum portion 42. In other words, regardingthe multiple suction ports provided on substrate stage PST, the suctionforce via suction ports 41′ located in the vicinity of notch portion NTof substrate P is set to be smaller than the suction force via suctionports 41 surrounding suction ports 41′.

Since, in this way, the suction force via suction ports 41′ located inthe vicinity of notch portion NT of substrate P is made to be smallerthan the suction force via the other suction ports 41, even when it isconfigured such that the gap between notch portion NT of substrate P andflat surface 31 (plate portion 30) is larger than the gap between sidesurface PB, other than the side surface of notch portion NT, ofsubstrate P and flat surface 31, and thus liquid 1 is likely topenetrate, the disadvantage that liquid 1 would penetrate between notchportion NT and flat surface 31 can be suppressed.

Furthermore, even if the liquid has penetrated to the underside surfaceside of substrate P, with the liquid flowing through notch portion NT ofsubstrate P and then flowing beyond top surface 33A of peripheral wall33, since the liquid can be captured by buffer space 47′, penetration ofthe liquid into first space 38 can be blocked. It is to be noted thatpreparing for such case, it may be configured such that the liquid thathas penetrated into buffer space 47′ is recovered.

It should be noted that it may also be configured such that withoutseparating the vacuum system connected to suction ports 41′ from thevacuum system connected to the other suction ports 41, the suction forcein the vicinity of notch portion NT of substrate P is made to besmaller. For example, it may be configured such that the bore diameterof suction ports 41′ in the vicinity of notch portion NT of substrate Pis made to be smaller than that of the other suction ports 41. Also, itmay be configured such that, regarding the multiple suction ports, thelayout density of suction ports in the vicinity of notch portion NT ismade to be smaller than that of the other suction ports surrounding thesuction ports in the vicinity of notch portion NT. Alternatively, it maybe configured such that no suction ports are provided in the vicinity ofnotch portion NT of substrate P. Still further, it may be configuredsuch that by, for example, closing flow channel 43′ connected to suctionports 41′ by using, for example, a valve, gas-suction is not performedthrough the suction ports provided in the vicinity of notch portion NTof substrate P.

It should be noted that when by making the suction force in the vicinityof cut portion (notch portion) NT of substrate P smaller, penetration ofthe liquid to the underside surface side of substrate P, it may beconfigured such that second peripheral wall 46′ is not formed.

Needless to say, also in the embodiment of FIGS. 25A and 25B, it may beconfigured such that, as with the embodiment shown in FIG. 4, sidesurface PB of substrate P, underside surface PC of substrate P, flatsurface 31 of plate portion 30, and/or inner side surface 36 of plateportion 30 are made to be liquid-repellent.

In the above-described embodiments, when the pressure of the liquidforming immersion region AR2 is high, the possibility that the liquidmay penetrate through gaps existing on substrate stage PST (e.g., thegap around substrate P) increases; and thus, to address this issue, itmay also be configured such that when immersion region AR2 is formed onsuch gaps on substrate stage PST, the pressure of the liquid is lowered.In particular, since there is the possibility that the pressure of theliquid may be high underneath supply ports 13A and 14A of liquid supplysystem 10, by making the pressure of the liquid smaller when supplyports 13A and 14A of liquid supply system 10 face the gaps on substratestage PST, penetration of the liquid through the gaps can be suppressed.

Furthermore, needless to say, the embodiments described with referenceto FIGS. 24 and 25 may be appropriately combined with the embodimentsdescribed with reference to FIGS. 9 to 23.

In each of the above-described embodiments, liquid 1 is constituted bypurified water. Purified water has the advantage that it is easilyavailable in bulk in, e.g., semiconductor manufacturing factories andalso the advantage that it does not adversely affect photoresist onsubstrate P, optical elements (lenses), etc. Furthermore, purified waterdoes not adversely affect the environment and contains scarcely anyimpurities; thus, the effect that it cleans the surface of substrate Pand the surface of the optical element provided at the end portion ofprojection optical system PL can be expected. It should be noted thatwhen the purity of the purified water supplied from, e.g., the factoryis low, it may be configured such that the exposure apparatus itself hasan ultra-purified water producing system.

The refractive index n of purified water (water) relative to exposurelight EL having a wavelength of about 193 nm is said to be approximately1.44, and when ArF excimer laser light (having 193 nm wavelength) isused as the light source of exposure light EL, the wavelength iseffectively shortened, on substrate P, as if multiplied by 1/n, i.e.,effectively becomes approximately 134 nm, and thus, a high resolutioncan be obtained. Furthermore, since the depth of focus increases byapproximately n times, i.e., approximately by 1.44 times, compared withthat in the air, when securing of the depth of focus on par with thedepth of focus realized when the projection optical system is used inthe air suffices, the numerical aperture of the projection opticalsystem PL can be further increased; which also improves the resolution.

When the liquid immersion method is used as described above, thenumerical aperture NA of the projection optical system may become 0.9 to1.3. When, in this manner, the numerical aperture NA of the projectionoptical system becomes large, random-polarized light conventionally usedas the exposure light may, because of its polarization effect, adverselyaffect the imaging performance; thus, a polarized light illuminationmethod is preferably used. In this case, it is preferable that byperforming linearly polarized light illumination in which thelongitudinal direction of the line pattern of the line-and-space patternon the mask (reticle) is aligned with the polarization direction, a lotof diffraction lights from S polarization components (TE polarizationcomponents), i.e., the diffraction lights from the polarizationcomponents having the polarization direction in line with thelongitudinal direction of the line pattern are emitted from the patternof the mask (reticle). When the space between projection optical systemPL and the resist applied to the surface of substrate P is filled withthe liquid, the transmittance at the resist surface of the diffractionlights from S polarization components (TE polarization components),which contribute to the improvement of the contrast, is higher comparedwith the case where the space between projection optical system PL andthe resist applied to the surface of substrate P is filled with the gas(air), a high imaging performance can be obtained even in the case wherethe numerical aperture NA of the projection optical system is over 1.0.Furthermore, a phase shift mask, an oblique incidence illuminationmethod (in particular, the dipole illumination method), as disclosed inJapanese Unexamined Patent Application, First Publication No.H06-188169, which meets the longitudinal direction of the line pattern,etc. may be appropriately combined with the above configuration, whichworks more effectively.

It should be noted that, for example, when by using, for example, ArFexcimer laser light as the exposure light and using projection opticalsystem PL having a reduction magnification of about ¼, a fineline-and-space pattern (e.g., line-and-space of about 25 to 50 nm) isexposed onto substrate P, depending on the structure of mask M (e.g.,the fineness of the pattern or the thickness of chrome), mask M acts asa polarization plate due to the wave guide effect, and the emittedamount of the diffraction lights from S polarization components (TEpolarization components) becomes larger than the emitted amount of thediffraction lights from P polarization components (TM polarizationcomponents), which lower the contrast, and thus, even when mask M isilluminated with random-polarized light, a high resolution performancecan be obtained even in the case where the numerical aperture NA of theprojection optical system PL is 0.9 to 1.3, although the above-describedlinearly polarized light illumination is preferably employed.Furthermore, although, for example, when a very fine line-and-spacepattern on mask M is exposed onto substrate P, there is the possibilitythat the emitted amount of the diffraction lights from P polarizationcomponents (TM polarization components) becomes larger than the emittedamount of the diffraction lights from S polarization components (TEpolarization components) due to the wire grid effect, since, forexample, when by using, for example, ArF excimer laser light as theexposure light and using projection optical system PL having a reductionmagnification of about ¼, a line-and-space pattern of more than 25 nm isexposed onto substrate P, the emitted amount of the diffraction lightsfrom S polarization components (TE polarization components) is largerthan the emitted amount of the diffraction lights from P polarizationcomponents (TM polarization components), a high resolution performancecan be obtained even in the case where the numerical aperture NA of theprojection optical system is 0.9 to 1.3.

Furthermore, not only the linearly polarized light illumination in whichthe longitudinal direction of the line pattern on the mask (reticle) isaligned with the polarization direction, but also the combination, asdisclosed in Japanese Unexamined Patent Application, First PublicationNo. H06-53120, of the polarized light illumination method, in which thelights used are linearly polarized in the tangential directions relativeto a circle, of which center is the optical axis, and an obliqueincidence illumination method is effective. In particular, in the casewhere the pattern of the mask (reticle) includes not only line patternswhich extend in a predetermined single direction but also line patternswhich extends in multiple different directions, by using, as alsodisclosed in Japanese Unexamined Patent Application, First PublicationNo. H06-53120, the polarized light illumination method, in which thelights used are linearly polarized in the tangential directions relativeto a circle, of which center is the optical axis, in combination with anannular illumination method, a high resolution performance can beobtained even in the case where the numerical aperture NA of theprojection optical system is large.

In the embodiments, optical element 2 is attached to the end ofprojection optical system PL, and by this lens, the opticalcharacteristics of projection optical system PL (spherical aberration,coma aberration, etc.) can be adjusted. It should be noted that as theoptical element to be attached to the end of projection optical systemPL, an optical plate used for the adjustment of the opticalcharacteristics of projection optical system PL may be utilized.Alternatively, a plane parallel plate that can transmit exposure lightEL may be utilized.

It should be noted that if the pressure, caused by the flow of liquid 1,of the space between the optical element located at the end ofprojection optical system PL and substrate P is high, it may beconfigured such that the optical element is rigidly fixed so as not tomove due to the pressure, instead of making the optical elementreplaceable.

It should be noted that while, in the embodiments, it is configured suchthat the space between projection optical system PL and the surface ofsubstrate P is filled with liquid 1, it may also be configured, forexample, such that the space is filled with liquid 1 in the conditionthat a cover glass constituted by a plane parallel plate is attached tothe surface of substrate P.

It should be noted that while, in the embodiments, liquid 1 is water,liquid 1 may be a liquid other than water. For example, when the lightsource of exposure light EL is an F₂ laser, the F₂ laser light does nottransmit through water, and thus, as liquid 1, a fluorofluid that cantransmit the F₂ laser light, such as perfluoropolyether (PFPE) orfluorochemical oil, may be used. Furthermore, as liquid 1, a material(e.g., cedar oil) that can transmit exposure light EL, has a highrefractive index as high as practicable, and does not affect projectionoptical system and the photoresist applied to the surface of substrate Pcan also be used. Also in this case, the surface treatment is applied inaccordance with the polarity of liquid 1.

It is to noted that regarding substrate P of each of the above-describedembodiments, not only a semiconductor wafer for manufacturing asemiconductor device, but also a glass substrate for a display device, aceramic wafer for a thin film magnetic head, a master mask or reticle(synthetic quartz or silicon wafer), etc. can be used.

Regarding exposure apparatus EX, in addition to a scan type exposureapparatus (scanning stepper) in which while synchronously moving mask Mand substrate P, the pattern of mask M is scan-exposed, astep-and-repeat type projection exposure apparatus (stepper) in whichthe pattern of mask M is exposed at one time in the condition that maskM and substrate P are stationary, and substrate P is successively movedstepwise can be used. Also, the present invention can be applied to astep-and-stitch type exposure apparatus in which at least two patternsare transferred onto substrate P in a partially overlapping manner.

Furthermore, the present invention can be applied to a stitch typeone-shot exposure apparatus in which in the state that a first patternand substrate P are substantially stationary, the reduction image of thefirst pattern is exposed at one time by using a projection opticalsystem (e.g., a refraction type projection optical system that has areduction magnification of ⅛ and includes no reflecting element), andthereafter, in the state that a second pattern and substrate P aresubstantially stationary, the reduction image of the second pattern isexposed at one time onto substrate P by using the projection opticalsystem in a manner that the first pattern image and the second patternimage partially overlap with each other.

Also, the present invention can be applied to a twin stage type exposureapparatus, which is disclosed in, e.g., Japanese Unexamined PatentApplication, First Publication No. H10-163099, Japanese UnexaminedPatent Application, First Publication No. H10-214783, and PublishedJapanese Translation No. 2000-505958.

Regarding the type of exposure apparatus EX, the present invention isnot limited to an exposure apparatus, which exposes a semiconductorpattern onto substrate P, for manufacturing semiconductor devices, butcan also be applied to a variety of exposure apparatuses, e.g., anexposure apparatus for manufacturing liquid crystal display devices or adisplays, an exposure apparatus for manufacturing thin film magneticheads, an exposure apparatus for manufacturing image pickup devices, andan exposure apparatus for manufacturing reticles or masks.

When using a linear motor (see U.S. Pat. Nos. 5,623,853 or 5,528,118) insubstrate stage PST or mask stage MST, either air-cushion type linearmotor using an air bearing or a magnetic levitation type linear motorusing a Lorentz force or reactance force may be used. Furthermore, eachof substrate stage PST and mask stage MST may be either of a type movingalong a guide or of a guideless type having no guide.

As the driving mechanism for each of substrate stage PST and mask stageMST, a planar motor in which by making a magnet unit in which magnetsare two-dimensionally arranged and an armature unit in which coils aretwo-dimensionally arranged face each other, each of substrate stage PSTand mask stage MST is driven by an electromagnetic force may be used. Inthis case, either one of the magnet unit and the armature unit isattached to stage PST or stage MST, and the other unit is attached tothe moving surface side of stage PST or stage MST.

A reaction force generated by the movement of substrate stage PST maybe, as described in Japanese Unexamined Patent Application, FirstPublication No. H08-166475 (U.S. Pat. No. 5,528,118), mechanicallyreleased to the floor (earth) by use of a frame member so that the forcedoes not transmit to projection optical system PL.

A reaction force generated by the movement of mask stage MST may be, asdescribed in Japanese Unexamined Patent Application, First PublicationNo. H08-330224 (U.S. Pat. No. 5,874,820), mechanically released to thefloor (earth) by use of a frame member so that the force does nottransmit to projection optical system PL.

Exposure apparatus EX according to the embodiments of the presentapplication is built by assembling various subsystems, including eachelement listed in the claims of the present application, in such amanner that prescribed mechanical accuracy, electrical accuracy, andoptical accuracy are maintained. In order to ensure the variousaccuracies, prior to and after the assembly, every optical system isadjusted to achieve its optical accuracy, every mechanical system isadjusted to achieve its mechanical accuracy, and every electrical systemis adjusted to achieve its electrical accuracy. The process ofassembling each subsystem into the exposure apparatus includesmechanical interfaces, electrical circuit wiring connections, and airpressure plumbing connections between each subsystem. Needless to say,there is also a process where each subsystem is assembled prior to theassembling of the exposure apparatus from the various subsystems. Oncompletion of the process of assembling the various subsystems in theexposure apparatus, overall adjustment is performed to make sure thatevery accuracy is maintained in the complete exposure apparatus.Additionally, it is desirable to manufacture the exposure apparatus in aclean room, in which the temperature, purity, etc. are controlled.

As shown in FIG. 26, micro devices such as semiconductor devices aremanufactured by a series of steps, including: step 201 in which themicro device's function and performance design is performed; step 202 inwhich a mask (reticle) is manufactured based on the design step; step203 in which a substrate, the device's base material, is manufactured;step 204 in which the mask pattern is exposed onto the substrate byexposure apparatus EX according to the above-described embodiments;device assembly step 205 (including the dicing process, bonding process,and packaging process); inspection step 206.

In accordance with the present invention, even when exposing edge areasof a substrate, the exposure can be performed in a condition that aliquid immersion region is formed well and that penetration of theliquid and flowing out of the liquid to the outside of a substrate stageare prevented, and devices having a desired performance can bemanufactured.

1. An exposure apparatus which exposes a substrate by projecting apattern image onto the substrate through a liquid, the exposureapparatus comprising: a projection optical system by which the patternimage is projected onto the substrate; and a movable member which ismovable relative to the projection optical system, wherein aliquid-repellent member, at least a part of a surface of which isliquid-repellent, is provided detachably on the movable member, theliquid-repellent member being different from the substrate, wherein agap is formed between the liquid-repellent member and the substrate heldby the liquid-repellent member, and wherein the gap is sized so that adistance between the substrate and the liquid-repellent member inconjunction with the liquid-repellent surface of the liquid-repellentmember forms a barrier that suppresses the flow of the liquid throughthe gap.
 2. The exposure apparatus according to claim 1, wherein themovable member has an interferometer-mirror used for obtaining positioninformation of the movable member.
 3. The exposure apparatus accordingto claim 1, wherein the substrate is moved relative to the projectionoptical system during the exposure by moving the movable member.
 4. Theexposure apparatus according to claim 3, wherein the liquid-repellentmember includes a substrate holder on which the substrate is retained.5. The exposure apparatus according to claim 4, wherein the substrateholder includes a peripheral wall and a supporting portion disposedinside the peripheral wall, and holds the substrate on the supportingportion by applying a negative pressure to an inner space surrounded bythe peripheral wall and a bottom surface of the substrate.
 6. Theexposure apparatus according to claim 5, wherein a top surface of theperipheral wall is liquid-repellent.
 7. The exposure apparatus accordingto claim 5, wherein an outer space is provided on the outside of theperipheral wall, the outer space surrounds the peripheral wall, and apressure of the outer space is made to be lower than that of the innerspace.
 8. The exposure apparatus according to claim 3, wherein theliquid repellent surface of the liquid-repellent member faces a part ofa surface of the substrate during the exposure.
 9. The exposureapparatus according to claim 8, wherein the surface of the substrate,which faces the liquid repellent surface during the exposure, includes abottom surface of the substrate.
 10. An exposure method for exposing asubstrate by projecting a pattern image onto the substrate through aliquid, the exposure method comprising: attaching a liquid-repellentmember, at least part of a surface of which is liquid-repellent, on amovable member; loading the substrate onto the liquid-repellent memberso that the liquid-repellent surface of the liquid-repellent member andthe substrate form a gap; and exposing the substrate by projecting thepattern image through the liquid, wherein the gap is sized so that adistance between the substrate and the liquid-repellent member inconjunction with the liquid-repellent surface of the liquid-repellentmember forms a barrier that suppresses the flow of the liquid throughthe gap.
 11. The exposure method according to claim 10, wherein thesubstrate is moved relative to a projection optical system during theexposure by moving the movable member.
 12. The exposure method accordingto claim 10, wherein the liquid-repellent member includes a substrateholder on which the substrate is retained.
 13. The exposure methodaccording to claim 12, wherein the substrate holder includes aperipheral wall and a supporting portion disposed inside the peripheralwall, and holds the substrate on the supporting portion by applying anegative pressure to an inner space surrounded by the peripheral walland a bottom surface of the substrate.
 14. The exposure method accordingto claim 13, wherein a top surface of the peripheral wall isliquid-repellent.
 15. The exposure method according to claim 10, whereinthe liquid repellent surface of the liquid-repellent member faces a partof a surface of the substrate during the exposure.
 16. The exposuremethod according to claim 15, wherein the surface of the substrate,which faces the liquid repellent surface during the exposure, includes abottom surface of the substrate.